Ikco SAMAND Service Manual
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Ikco SAMAND Service Manual

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SAMAND
(XU7JPL3)
Service Manual
Heating & Ventilation

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Summary of Contents for Ikco SAMAND

  • Page 1 SAMAND (XU7JPL3) Service Manual Heating & Ventilation...
  • Page 2 Product: Chapter: Section: SAMAND XU7JPL3 Heating and Ventilation SAMAND Service Manual Foreword: This Service Manual contains descriptions of the following categories for the Samand: Heating and Ventilation This manual should be used as service manual and s workbook for training instructors and technicians. We reserve the right to introduce...

  • Page 3: Table Of Contents

    Contents Heating and ventilation ......... . Special tools Special tools .

  • Page 4: Heating And Ventilation

    Heating and Ventilation...

  • Page 5: Special Tools

    Special tools Special tools Robinair charging station T ool Number Robinair Charging Station Robinair leak detector T ool Number Robinair Leak Detector Technotest electronic thermometer T ool Number Technotest Electronic Thermometer...
  • Page 6 Three legged puller T ool Number Three Legged Extractor Adjustable peg spanner T ool number Adj Peg Spanner Compressor dip stick T ool number Dipstick...
  • Page 7 Special tools Drive plate extractor T ool Number Drive Plate Extractor End adapter T ool Number End Adapter Feeler gauge T ool Number Feeler Gauges...

  • Page 8: Technical Data

    T echnical data Technical data Compressor Type SD7H15 Cylinder volume 154,9cc Oil capacity 135cc Clutch type Speed 8000 RPM Max Wieght 7.2kg Oil type SP10 OR SP20 W710D003 Expansion Valve Egelhof Type Capacity Static overheating W710D006 R134a Capacity 600gr...

  • Page 9: Temperature Sensor

    T echnical data Temperature sensor Reference required Pressostat Data -0.5 bar on Data -1 bar on -1.5 off W710D005...

  • Page 10: Torque Settings

    Torque settings W710D002 1 Compressor inlet union 3mdaN 3-3,5mdaN 2 Compressor outlet union 3mdaN 3-3,5mdaN 3 Union on damper chamber 2 - 3mdaN 3-3,5mdaN 4 Condenser inlet pipe 1,5 - 2,5mdaN 2-2,5mdaN 5 Dehydration reservoir outlet union 1,5 - 2mdaN 1,2-1,5mdaN 6 Condenser outlet/dehydration reservoir inlet union 1,5 - 2mdaN...

  • Page 11: Technical Description

    T echnical description Technical description System overview W710D001 Heating and ventilation Pressure relief valve Blower Dehydration reservoir Evaporator Condenser Electronic thermostat Compressor Heater matrix...

  • Page 12: Function Of Ac System

    T echnical description Function of AC system Compressor The refrigerant arrives at the compressor from the evaporator at low pressure and as a gas. It is compressed in the compressor, which increases its pressure and temperature. The warm, gaseous refrigerant is then forced into the condenser. W710D003 Condenser The hot, high pressure refrigerant is pumped by the...
  • Page 13 T echnical description Expansion valve The refrigerant which enters the expansion valve is in liquid form with high pressure and temperature. The task of the expansion valve is to adjust the amount of refrigerant which is sprayed into the evaporator. The valve does not allow in more refrigerant than can be evaporated at any one time.

  • Page 14: Adjustment And Replacement

    Adjustments and replacement Refrigerant circuit - draining, vacuum extraction and refilling Draining High pressure valve. Low pressure valve. Note The high pressure valve is fitted on the pipe with the smallest diameter. Drain the circuit via the low pressure valve (gaseous zone) very slowly to avoid draining the compressor oil.

  • Page 15: Compressor

    Adjustment and replacement Compressor To remove Drain the refrigerant circuit. Remove engine under tray, (see Book 2 for reference). Remove wheel arch liners, (see Book 2 for reference). Remove accessory drive belt. " W710R001 Unplug electrical connector. Disconnect compressor inlet union. Disconnect compressor outlet union.
  • Page 16 Adjustment and replacement Remove upper fixing bolts. 10 Remove compressor. To fit Fit in reverse order. Note Ensure washers and spacers are correctly fitted. All fixing bolts have a tightening torque of 5mdaN. W710R004...

  • Page 17: Compressor Drive Plate

    Adjustment and replacement Compressor drive plate To remove Remove compressor from car. Attach peg spanner. Slacken the central locking nut and remove. W710R063 Fit the extractor special tool. Extract the drive plate. To fit Fit in reverse order. Note Fit the old nut and tighten to 3,5-4 mdaN. Check and adjust the air gap if required.

  • Page 18: Compressor Drive Pulley

    Adjustment and replacement Compressor drive pulley To remove Remove compressor from car. Remove the drive plate. Remove circlip, washers and key. W710R061 Fit the extractor special tool and remove pulley. To fit " Fit in reverse order. Note " Fit the old nut and tighten to 3,5-4 mdaN. Check and adjust the air gap if required.

  • Page 19: Compressor Oil Level

    Adjustment and replacement Compressor oil level To check Remove plug. Turn compressor pulley by hand to reveal: a. The inclination of the control plate. b. The connecting rod, while looking through the oil filler hole. W710R059 Position the chamfered face of the dip stick against the body of the compressor.

  • Page 20: Compressor Air Gap

    Adjustment and replacement Compressor air gap To measure Measure the air gap between the drive plate and the pulley. Measure in at least 3 places. The air gap should be 0,4 - 0,8mm. W710R005 Adjustment If the air gap is incorrect, remove drive plate retaining nut.

  • Page 21: Condenser

    Adjustment and replacement Condenser To remove Drain the cooling system. Drain the refrigerant system. Disconnect all the radiator inlet and outlet " hoses. Unclip and remove the radiator upwards. W710R008 Disconnect the condenser inlet fixing. Remove nut from inlet pipe support bracket. Disconnect the condenser outlet fixing.

  • Page 22: Dehydration Reservoir

    Adjustment and replacement Dehydration reservoir To remove Drain the cooling system. Remove pressostat. Disconnect the two top freon pipes. W710R011 Remove nut from reservoir bracket. Lift up and remove dehydration reservoir. To fit Fit in reverse order. Note Use new O-rings on the end of the freon pipes. Check compressor oil level.

  • Page 23: Evaporator

    Adjustment and replacement Evaporator To remove Drain the refrigerant circuit. Remove floor console and fascia, (see Book 9 for reference). Remove heater. W710R013 Remove 3 screws. Remove expansion chamber. " " " W710R014 Remove 1 screw and release matrix pipes. Remove 2 screws and pull out heater matrix.
  • Page 24 Adjustment and replacement Remove 2 screws. Remove blower flap operating motor and release electrical connector from blower housing. W710R016 10 Remove clips from blower motor casing. Remove clips from outer evaporator casing. W710R017 12 Remove the screw. 13 Remove evaporator upper casing. 14 Remove sensor.
  • Page 25 Adjustment and replacement 15 Remove evaporator. To fit Fit in reverse order. Note Use new O-rings on the ends of the freon pipes. Check the compressor oil. Charge the freon circuit. W710R030...

  • Page 26: Expansion Chamber

    Adjustment and replacement Expansion chamber To remove Drain the refrigerant circuit. Disconnect the air inlet pipe. W710R019 Remove 2 nuts. Release the joints and pipes. Remove bottom screw. W710R020 Replace the screw with a threaded rod approximately 8cm in length. Remove screw.
  • Page 27 Adjustment and replacement Remove expansion chamber. To fit Fit in reverse order. Note Use new O-rings on R134a pipes. Check compressor oil. Charge the R134a circuit. W710R029...

  • Page 28: Heater Blower

    Adjustment and replacement Heater blower To remove Remove RH fascia lower closing panel. W710R022 Unclip electrical harness. " Unplug electrical connector. Remove 3 screws. " " W710R023 Remove by lowering the blower downward. To fit Fit in reverse order. W710R028...

  • Page 29: Blower Module

    Adjustment and replacement Blower module To remove Unplug 2 connector's. Set aside electrical harness. W710R031 Separate the tongue. Remove 2 screws. " " Remove blower module. W710R032 Insert a screwdriver in the slots to release and remove the motor from casing. To fit Fit in reverse order.

  • Page 30: Air Conditioning Control Unit

    Adjustment and replacement Air conditioning control unit To remove Remove radio. Remove centre console trim. Release the control unit by pushing from the rear, use the radio location hole to gain access. W710R025 Remove the clip and release the cable. Unplug the electrical connector.

  • Page 31: Air Conditioning Control Card

    Adjustment and replacement Air conditioning control card To remove Remove control unit from centre console. Remove 3 control knobs. Remove control panel cover. W710R034 Remove 2 screws. " " W710R035 Separate the components. To fit Fit in reverse order. Note Before refitting the panel put the cursors in their mid positions.

  • Page 32: Heater Matrix

    Adjustment and replacement Heater matrix To remove Depressurise the cooling system. Remove the air inlet pipe. Clamp the matrix inlet and outlet pipes. W710R037 Remove floor console and fascia. Remove fixings. Note Place a container under the matrix unions. Remove 2 screws. W710R038 Remove matrix.

  • Page 33: Heater

    Adjustment and replacement Heater To remove Remove floor console and floor air ducts. Remove fascia. (see Book 9 for reference on steps 1 and 2). Remove 1 bolt from floor mounted bracket, located on the bottom right hand side of the heater.
  • Page 34 Adjustment and replacement Remove fixings for matrix inlet and outlet pipe. Note Place a container under the matrix pipes before removing. W710R043 10 From the engine bay, remove 2 retaining bolts and collect 2 connector’s. From inside the scuttle chamber, remove 1 retaining bolt and collect 1 washer.

  • Page 35: Coolant Temperature Unit

    Adjustment and replacement Coolant temperature unit To remove Unplug electrical connector. Remove 2 nuts. Remove coolant temperature unit. To fit Fit in reverse order. W710R046...

  • Page 36: Electronic Thermostat

    Adjustment and replacement Electronic thermostat To remove Remove RH and LH footwell heater trims. Remove 1 screw from the electrical connector support bracket and unplug connector's. W710R047 Unplug electrical connector from electronic thermostat. Remove 2 screws. " Remove thermostat. To fit Fit in reverse order.

  • Page 37: Scuttle Air Intake Filter

    Adjustment and replacement Scuttle air intake filter To remove Remove wiper arm. Remove scuttle grill. Remove 2 screws and release plastic cover over intake filter. W710R049 Lift out filter. " To fit Fit inr reverse order. W710R050...

  • Page 38: Evaporator Sensor

    Adjustment and replacement Evaporator sensor To remove Remove LH footwell heater trim. W710R051 Unclip sensor from casing. Unplug connector and remove sensor. To fit Fit in reverse order. W710R052...

  • Page 39: Air Conditioning Compressor Relay

    Adjustment and replacement Air conditioning compressor relay To remove Remove 3 screws for fascia LH lower closing panel. W710R053 Remove 3 nuts and 1 screw, drop down the relay bracket to expose relays. W710R054 Remove compressor relay. To fit Fit in reverse order. &...

  • Page 40: Blower Relay

    Adjustment and replacement Blower relay To remove Remove 3 screws for fascia LH lower closing panel. W710R056 Remove 3 nuts and 1 screw, drop down the relay bracket to expose relays. W710R057 Remove blower relay. To fit Fit in reverse order. &...

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