A/C System - Flush After Compressor Failure
412-04V8 XJ Series/XK8
DATE
3/99
MODEL
1997 MY-ON XK8 Range
1998 MY-ON V8 XJ Series
VIN
001001-ON
812256-ON
Compressor Failure - Flushing Refrigerant System
Issue:
In the event of internal failure in any air conditioning refrigerant compressor, metallic particles are circulated through the entire refrigerant system. Since the walls of the system components and pipes are coated with compressor lubricating oil, the metallic particles may at first stick to the components. If not cleared from the system, however, these particles will eventually pass through the system, where they can block small orifices or damage a replacement compressor. It is mandatory that any particles be flushed from a refrigerant system before installing a new compressor and receiver/drier unit. The necessary procedure is detailed below.
Action:
While the refrigerant system is 'open' to permit the replacement of a refrigerant compressor and receiver/drier, following any compressor failure, flush the system before installing these components.
The following procedure assumes that the 'Robinair' equipment (available through SPX - Kent Moore) is ready for immediate use - connected to a workshop compressed air supply, and with clean flushing fluid (8 liters-2 US Gallons) ready in the flushing tank.
Warning:
Observe all the following safety precautions:
Do not smoke.
Work in a well ventilated area.
Ensure that no open flames or other source of solvent ignition are present in the working area.
Wear goggles.
Wear gloves.
1. With the vehicle at ground level, replace the contaminated Receiver/Drier with the dummy Receiver/Drier unit. Replace any damaged O-rings. Fully tighten the hose/pipe connections.
2. Using a 4-post lift, raise the vehicle to a convenient working height.
3. Disconnect and remove the defective compressor.
4. Examine the seals at the pipe connections to the compressor. If damaged, install new seals.
5. Install the inlet & outlet adapter (Tool No. 412-121) in place of the compressor, by running the long bolts from the rear, through the compressor hose/pipe block connector and the adapter. At the front, install and tighten the nuts provided, to ensure a leak proof seal.
6. Connect the blue (outlet) hose from the 'Robinair' equipment to the left connector (as viewed from the front of the vehicle, and as in Illustration 1) of the adapter. Connect the red (Return) hose from the 'Robinair' equipment to the right connector of the adapter.
Caution:
The refrigeration systems on XK8 and V8 XJ Series vehicles may only be flushed in one direction, following the normal circulation route from compressor, via condenser, receiver/drier, evaporator and return to compressor.
Disregard any instructions which may be supplied with this general-purpose equipment concerning reverse-flushing of individual components or the complete system. This is not permitted on the above Jaguar vehicles.
7. Turn the control valve of the 'Robinair' equipment to 'FLUSH'. Allow the valve to remain in this position until the entire contents of the supply tank have been flushed through the vehicle system. This will be apparent when air bubbles mixed with flushing fluid are visible in the transparent return hose, and by a change in the sound generated. Once ALL fluid bubbles have been returned to the 'Robinair' equipment, turn the control valve to the 'PURGE' position, to allow filtered air to pass through the vehicle refrigerant system. Continue to allow air to pass through the vehicle system for AT LEAST 5 minutes, to remove as much vapor of the flushing fluid as possible. Then return the control valve to 'OFF'.
8. Disconnect the outlet and return hose 'quickfit' connectors from the compressor adapter. Remove the Dummy Receiver/Drier.
9. Install the replacement compressor and replacement receiver/drier. Install new 0-ring seals at ALL pipe joints which were disconnected.
10. Connect the normal refrigerant degassing/charging equipment to the system. Operate the equipment in the normal manner to evacuate the system.
Once the normal maximum vacuum has been attained, continue to evacuate the system, with the vacuum pump operating, for AT LEAST 30 minutes, to ensure that all traces of vapor from the flushing fluid are evacuated.
The system may then be filled with R134A refrigerant following standard procedures.
SETTING - UP 'POWERFLUSH PLUS' EOUIPMENT
1. It will be necessary to obtain a 1/4 inch male fitting for connection of the equipment. A hose and hose clamp for connection to the workshop compressed air supply will also be required.
2. Place the control valve on the front panel to the 'OFF' position. Place the two drain valves on the rear of the equipment to 'OFF'.
3. Initial Solvent Fill. Pour approximately 7.5 liters (2 US Gallons) of 'Robinair' 'PowerFlush' into the flushing tank until the level rises to the 'FULL' mark on the dipstick.
SOLVENT RECYCLING AND DRAINING
1. After flushing a refrigerant system and disconnecting the equipment from the vehicle, turn the control valve to 'RECYCLE'.
The air supply will recycle the flushing solvent back to the supply tank, via a particle filter, ready for reuse.
2. A fill of solvent may be used a number of times. It should then be drained off, and replaced by fresh solvent. The necessity to change the solvent may be indicated by severe discoloration-ion visible as the fluid passes through the transparent flexible hoses, or by slow recycling as in (1) above, indicating that the particle filter should be replaced along with the solvent.
3. To drain solvent, place a suitable waste disposal container in turn under each of the two drain valves on the lower rear of the cabinet. Open each valve in turn until the solvent is fully drained.
SOLVENT DISPOSAL:
Follow appropriate local procedures and legislation for solvent disposal.
Where appropriate, a specialist disposal contractor should be employed.
The solvent contains Terpene Hydrocarbons (pinanes).
NEVER DISPOSE OF 'POWERFLUSH PLUS SOLVENT' INTO PUBLIC DRAINS OR SEWERAGE SYSTEMS
Warning:
Health hazards of 'powerflush plus' solvent:
Skin: Prolonged contact of the fluid with the skin may cause moderate irritation or dermatitis.
Eyes: Fluid splashed in the eyes should be flushed for at least 15 minutes while holding the eyelids open. If irritation persists, seek medical attention.
Ingestion: May result in vomiting. DO NOT INDUCE VOMITING. SEEK IMMEDIATE MEDICAL ATTENTION. If vomiting occurs spontaneously, keep the head BELOW the hips to prevent aspiration of fluids into the lungs. Minute amounts of liquid aspirated into the lungs may have serious consequences.
Advise the physician that the ingested fluid contains Terpene Hydrocarbons. A 24-hour Emergency Helpline is available to PHYSICIANS ONLY by calling CHEM TREC in USA Tel. +1 800 424 9300.
Product Reference: 29 CFR 1910.1200 and/or 40 CFR 350.
EQUIPMENT MAINTENANCE
Replace the Particle Filter (spin-on filter cartridge) each time the fill of flushing solvent is replaced.
Replacement Filter: Fram Part No. PH3980 or equivalent non-bypass spin-on cartridge filter.
The equipment also contains a filter/drier containing a desiccant. Replace the filter/drier when there is an increase in the time required to recycle the fill of solvent to the supply tank.
Replacement: Standard 3/8 flare-fitting commercial filter/drier with XH7 or XH9 desiccant.
Replace the activated charcoal filter in the cabinet when there is an increase in odors during the flushing and purging operations
Replacement filters for the above applications may be obtained through the local 'Robinair' distributor, who will also supply 'PowerFlush' solvent, Robinair Part No.17565. (2 US Gallons 3.785 liters).
Recommended Equipment:
'Robinair' Model 17570 'PowerFlush Plus' Air Conditioning Flusher and Solvent Recycler, or equivalent proprietary equipment.
Connection Adapters and Dummy Receiver/Driers - Jaguar Special Tools, as below, from Adapter Kit 412-S119:
GLOBAL
ADAPTER MODEL TOOL NO.
Compressor Inlet & Outlet Adapter XK8, V8 XJ Series 412 - 121
complete with 2 bolts & 2 nuts
Dummy Receiver/Drier V8 XJ Series 412 - 124
Dummy Receiver/Drier XK8 412 - 123
Recommended Flushing Solvent:
'Robinair' 'PowerFlush'TM Solvent.
This solvent is available from 'Robinair' distributors.
'ROBINAIR' DISTRIBUTORS/CONTACT ADDRESSES:
ADDRESS MARKETS COVERED
SPX Corporation Tel 419-485-5561 USA
1224 Robinair Way FAX 419-485-8300
Montpelier OH 43543
SPX Corporation Tel 1-800-267-2327 Canada
3375 14th Ave. FAX 1-800-206-4014
Unit 7 & 8
Markham Ontario
Alberto y Amigos Tel/FAX 52-8-359-1608 Mexico
Parque Espana 287
Col. Buenos Aires
N.L. Mexico C.P. 64000
Monterrey
Parts Information:
All Jaguar replacement Parts required should be ordered via Jaguar Parts Operations.
Warranty Information:
FAULT R.O. TIME
CODE NUMBER DESCRIPTION ALLOWANCE
JB XF 49 82.30.14 Flushing refrigerant system 0.65 hrs.