Warning

WARNING

All operations are to be carried out with utmost care and attention to avoid personal injuries.

There are many moving parts, hot parts and live electric wires in the engine compartment.

Always remember the following precautions when working on the engine compartment:

• Switch off the engine and wait for it to cool.
• Do not smoke.
• Do not use naked flames.
• Make sure there is a fire extinguisher at hand.

For some procedures the use of specific tools is indicated. The use of these tools is necessary to operate in safety.

Follow all safety precautions in force in the workshop. Where relevant, follow the specific safety precautions specified in this Manual to avoid dangerous situations.

For the use of chemical products follow carefully the safety precautions specified in the safety schedule that the supplier must give to the user (for Italy according to the law n. 47/1992).

When the engine is hot the cooling system is under pressure: therefore wait until the engine has cooled and the pressure in the cooling circuit has lowered before starting any intervention on the system components.

The air conditioner cooling circuit uses ecological fluid R134a. If it is necessary to intervene on the cooling circuit, scrupulously observe these safety precautions :

• Do not use naked flames and work in ventilated environments with the intake system on. In fact, should there be a leakage in the climate control system or equipment for the emptying / recovery /recharging, the R134a fluid can become toxic if very near naked flames or in the presence of some metals such as magnesium or aluminium under the form of particles or powder.
• Avoid prolonged contact of the skin with the R134a fluid when evaporating, because the low temperature (- 26.5 °C) it reaches to expand can cause cold burns. It is therefore advised to wear leather or thick fabric gloves.
• The eyes must be protected from contact with R134a fluid, because the excessive and instantaneous low temperature can be very harmful.
• Diffusion of R134a fluid in the air is a danger to the environment: to empty the cooling circuit use only the special equipment.
• Before starting to work on the electrical system (connectors, electrical components, wiring etc.) disconnect the battery.

WARNINGS

All operations are to be carried out with utmost attention and care to avoid damage to components.

To free parts that are stuck, knock lightly with an aluminium or lead hammer for ferrous materials; use a wooden or resin hammer for parts in light alloy.

When removing, check that parts, which should be marked, bear reference marks.

Use adhesive paper or clean cloths to suitably protect the parts of the engine that might let in dust or foreign matter remaining uncovered after disassembly.

When reassembling, lubricate the parts where necessary to avoid seizing during the initial period of operation.

When reassembling it is most important to respect the torques and setting data.

When reassembling change the seals, oil rings, spring washers, safety plates, self-locking nuts and all worn parts.

• Before starting any operations on the air conditioner system the circuit must be emptied and the R134a coolant recovered with the special equipment (see Op. 5040A10 Air conditioner cooling CIRCUIT - Dehydration and recharging).
• After disconnecting components from the system, close the disconnected fittings with sealing plugs to prevent the entry of moisture and impurities.
• At every disassembly replace the O-Rings of the pipe fittings. Only use green O-Rings, compatible with the coolant R134a.
• Lubricate the fitting threads with anti-freeze oil and tighten the fittings to the specified torque.
• R134a is NOT compatible with Freon R12 which was previously used in cooling circuits. NEVER under any circumstances use Freon R12, even in very small quantities in climate control systems designed to operate with R134a coolant.
• For the same reason ALL the system components are specifically intended for the use of R134a and are NOT interchangeable with those intended for the use of Freon R12.
• The emptying/recovery station is specifically designed for R134a.
• Also the anti-freeze oil for the compressor lubrication is specially for use with R134a and is different from that used in systems with Freon R12.