SAMAND

(XU7JPL3)

Service Manual
Heating & Ventilation
 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
change without prior notice.

I
 Contents
Heating and ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Special tools
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Technical data
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

R134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pressostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Technical description
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Function of AC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adjustment and replacement

Refrigerant circuit-draining, vacuum extraction and refilling . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Compressor drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Compressor drive pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Compressor oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Compressor air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Dehydration reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Expansion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Heater blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Blower module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Interior air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Air conditioning control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Air conditioning control card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Heater matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Coolant temperature unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Electronic thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Scuttle air intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Evaporator sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Air conditioning compressor relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Blower relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
 5

Heating and Ventilation

6 Special tools

Special tools
Robinair charging station
Tool Number

Robinair Charging Station

Robinair leak detector

Tool Number

Robinair Leak Detector

Technotest electronic
thermometer
Tool Number

Technotest Electronic Thermometer

 Three legged puller
Tool Number

Three Legged Extractor

Adjustable peg spanner

Tool number

Adj Peg Spanner

Compressor dip stick

Tool number

Dipstick
8 Special tools

Drive plate extractor

Tool Number

Drive Plate Extractor

End adapter
Tool Number

End Adapter

Feeler gauge
Tool Number

Feeler Gauges
 Technical data 9

Technical data
Compressor
Type SD7H15

Cylinder volume 154,9cc

Oil capacity 135cc

Clutch type PV

Speed 8000 RPM Max

Wieght 7.2kg

Oil type SP10 OR SP20

W710D003

Expansion Valve Egelhof

Type

Capacity

Static overheating

W710D006

R134a
+0
Capacity 600gr
-50
10 Technical data

Temperature sensor
Reference required

Pressostat
+
Data 2.5
-0.5 bar on

+
Data 17
-1 bar on

+
26 -1.5 off

W710D005
Torque settings

7 5 6 3 1

4 2

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 1,2-1,5mdaN

7 Pressure relief valve clamp 0,5 - 1mdaN 1,3mdaN

 Technical description 13

Technical description
System overview

1 2 3 4

8 7 6 5

W710D001

Heating and ventilation

1 Pressure relief valve 5 Blower

2 Dehydration reservoir 6 Evaporator

3 Condenser 7 Electronic thermostat

4 Compressor 8 Heater matrix

14 Technical 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

compressor into the condenser’s coiled tubes. The

coiled tubes are fitted with cooling flanges around which

air is circulated by the ventilation fan and the air

stream. As heat is always transferred from a warmer to

a cooler object, the hot refrigerant will transfer some of

its heat to the cooler air. The hot, gaseous refrigerant

will then lose some of it’s heat, start to condense and

thus become liquid.

W710D004

Receiver Drier
The refrigerant is stored and dried in the

receiver drier reservoir.

The refrigerant enters receiver drier reservoir as a liquid

under high pressure and with high temperature. It

passes through the filter, where it is receiver drier and

any particles removed. The refrigerant is then

transported, as a liquid, to the expansion valve.

The system’s pressure monitor is located on the

receiver drier rservoir and is called the pressostat.

W710D005
 Technical description 15

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.

W710D006

Evaporator
After the expansion valve, the refrigerant enters the

evaporator where it expands. The pressure in the

evaporator is considerably lower due to the suction

action in the compressor. When the refrigerant

expands, it becomes a gas (evaporator). Heat must be

added to make this happen. The heat is taken from the

air around the evaporator. The cooled air is then sent to

the interior of the car. The refrigerant then goes to the

compressor in the form of a gas.

W710D007
 Adjustments and replacement
Refrigerant circuit - draining, vacuum extraction and refilling
Draining
1 1 High pressure valve.

2 2 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.

W710R065

Refilling

Imperative
Before filling the circuit with refrigerant, it is necessary

to carry out a vacuum extraction to dry the circuit.

1 Connect the filling equipment to the service

valves.

2 Carry out a vacuum extraction

(draining time 15 minutes)

3 Check the sealing of the circuit:

The vacuum should be held for more than

5 minutes.

4 Carry out a pre-filling:

300g.

5 Check the sealing of the circuit.

6 Drain the refrigerant circuit.

7 Carry out a vacuum extraction

(draining time 30 minutes minimum).

8 Charge the circuit with the specified quantity of

refrigerant.
18 Adjustment and replacement

Compressor
To remove
1 Drain the refrigerant circuit.

2 Remove engine under tray,

(see Book 2 for reference).

3 Remove wheel arch liners,

(see Book 2 for reference).

4 Remove accessory drive belt.

W710R001

5 Unplug electrical connector.

6 Disconnect compressor inlet union.

5 6
7 Disconnect compressor outlet union.

7
W710R002

8 Remove lower fixings and collect spring

washers, centralising bush, plain washer and

tension pin.

8
8

W710R003
 Adjustment and replacement 19

9 Remove upper fixing bolts.

10 Remove compressor.

9 9

To fit
Fit in reverse order.

Note
Ensure washers and spacers are correctly fitted.

All fixing bolts have a tightening torque of 5mdaN.

10 W710R004
20 Adjustment and replacement

Compressor drive plate

To remove
1 Remove compressor from car.

2 Attach peg spanner.

3 Slacken the central locking nut and remove.

3
W710R063

4 Fit the extractor special tool.

5 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.

Fit a new nut in place of the old one and

tighten to 3,5-4 mdaN.

5
4 W710R064
 Adjustment and replacement 21

Compressor drive pulley

To remove
1 Remove compressor from car.

2 Remove the drive plate.

3 Remove circlip, washers and key.

2 W710R061

4 Fit the extractor special tool and remove

pulley.

To fit
4
Fit in reverse order.

Note
4 Fit the old nut and tighten to 3,5-4 mdaN.

Check and adjust the air gap if required.

Fit a new nut in place of the old one and

tighten to 3,5-4 mdaN.

W710R062
22 Adjustment and replacement

Compressor oil level

To check
1 1 Remove plug.

2 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

3 Position the chamfered face of the dip stick

against the body of the compressor.

Note
The dipstick must enter the compressor without

excessive constraint.

The value should be 6 graduations on the dipstick.

If required, adjust oil level to specified value.

3
4 Replace plug.

W710R060
 Adjustment and replacement 23

Compressor air gap

To measure
1 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
2 If the air gap is incorrect, remove drive plate

retaining nut.

3 Release drive plate and collect washers and

key.

4 Adjust the air gap by changing:

a. Thickness of the washers.

b. The number of washers.

44
2
3
W710R006

To fit
1 Refit the drive plate.

2 Fit the old nut and tighten to 3,5-4 mdaN.

3 Check and adjust the air gap if required.

4 Fit a new nut in place of the old one and

tighten to 3,5-4 mdaN.

2,4

W710R007
24 Adjustment and replacement

Condenser
To remove
1 Drain the cooling system.

2 Drain the refrigerant system.

3 Disconnect all the radiator inlet and outlet

4 hoses.

4 Unclip and remove the radiator upwards.

W710R008

7
5 Disconnect the condenser inlet fixing.

6 Remove nut from inlet pipe support bracket.

7 Disconnect the condenser outlet fixing.

6
5
W710R009

8 Remove the 2 condenser fixing screws.

9 Lift condenser and out to remove.

8 8

To fit
Fit in reverse order.

Note
Use new O-rings on the end of the freon pipes.

Check compressor oil level.

9
W710R010
 Adjustment and replacement 25

Dehydration reservoir
3
To remove
1 Drain the cooling system.

2 Remove pressostat.

3 3 Disconnect the two top freon pipes.

W710R011

4 Remove nut from reservoir bracket.

5 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.

5
4
W710R012
26 Adjustment and replacement

Evaporator
To remove
3 1 Drain the refrigerant circuit.

2 Remove floor console and fascia,

(see Book 9 for reference).

3 Remove heater.

W710R013

4 Remove 3 screws.

5 Remove expansion chamber.

4
4

4
5

W710R014

6 Remove 1 screw and release matrix pipes.

7 Remove 2 screws and pull out heater matrix.

7
7

W710R015
 Adjustment and replacement 27

8 Remove 2 screws.

9 Remove blower flap operating motor and

release electrical connector from blower

8 housing.

8
9

W710R016

10 Remove clips from blower motor casing.

11 Remove clips from outer evaporator casing.

11

10

W710R017

12 Remove the screw.

13 13 Remove evaporator upper casing.

14 Remove sensor.

14

W710R018
28 Adjustment and replacement

15 Remove evaporator.

To fit
15 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
 Adjustment and replacement 29

Expansion chamber
To remove
1 Drain the refrigerant circuit.

2 Disconnect the air inlet pipe.

W710R019

3 Remove 2 nuts.

4 Release the joints and pipes.

5 Remove bottom screw.

4 3
W710R020

6 Replace the screw with a threaded rod

approximately 8cm in length.

7 7 Remove screw.

W710R021
30 Adjustment and replacement

8 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
 Adjustment and replacement 31

Heater blower
To remove
1 Remove RH fascia lower closing panel.

W710R022

2 Unclip electrical harness.

4 3 Unplug electrical connector.

4 Remove 3 screws.

2
4

3 4

W710R023

5 Remove by lowering the blower downward.

To fit
Fit in reverse order.

W710R028
32 Adjustment and replacement

Blower module
To remove
1 Unplug 2 connector's.

2 Set aside electrical harness.

2 1 W710R031

3 Separate the tongue.

4 Remove 2 screws.

4 4 5 Remove blower module.

W710R032

6 Insert a screwdriver in the slots to release and

remove the motor from casing.

To fit
Fit in reverse order.

Note
Ensure the motor is fully home in the casing on

re-fitting.

W710R033
34 Adjustment and replacement

Air conditioning control unit

To remove
1 Remove radio.

2 Remove centre console trim.

3 Release the control unit by pushing from the

rear, use the radio location hole to gain

access.

3
1
2

W710R025

4 Remove the clip and release the cable.

5 Unplug the electrical connector.

4 5

W710R026

6 From underneath the unit remove the clip and

release cable.

7 Remove air conditioning control unit.

To fit
Fit in reverse order.

W710R027
 Adjustment and replacement 35

Air conditioning control card

To remove
1 Remove control unit from centre console.

2 Remove 3 control knobs.

3 3 Remove control panel cover.

2 2

W710R034

4 Remove 2 screws.

4 4

W710R035

5 Separate the components.

To fit
Fit in reverse order.

Note
Before refitting the panel put the cursors in their mid

positions.

W710R036
36 Adjustment and replacement

Heater matrix
To remove
1 Depressurise the cooling system.

2 Remove the air inlet pipe.

3 Clamp the matrix inlet and outlet pipes.

3
W710R037

4 Remove floor console and fascia.

5 5 Remove fixings.

Note
Place a container under the matrix unions.

6 Remove 2 screws.

6
6

W710R038

7 Remove matrix.

To fit
Fit in reverse order.

7 Note
Fit new O-rings to the matrix unions.

W710R039
 Adjustment and replacement 37

Heater
To remove
1 Remove floor console and floor air ducts.

2 Remove fascia.

(see Book 9 for reference on steps 1 and 2).

3 Remove 1 bolt from floor mounted bracket,

located on the bottom right hand side of the

heater.

W710R040

4 Depressurise the cooling system.

5 Remove air intake pipe.

7 6 Remove wiper arm.

7 Remove scuttle grill.

(see Book 11 for reference).

W710R041

8 Clamp the matrix inlet and outlet pipes.

8
W710R042
38 Adjustment and replacement

9 Remove fixings for matrix inlet and outlet pipe.

9
Note
Place a container under the matrix pipes before

removing.

W710R043

10 From the engine bay, remove 2 retaining bolts

10 11 and collect 2 connector’s.

11 From inside the scuttle chamber, remove 1

retaining bolt and collect 1 washer.

W710R044

12 Remove the heater unit.

12

To fit
Fit in reverse order.

Note
Fit new O-rings to the freon pipes.

W710R045
 Adjustment and replacement 39

Coolant temperature unit

To remove
2 1 Unplug electrical connector.

1 2 Remove 2 nuts.

3 Remove coolant temperature unit.

3 To fit
Fit in reverse order.

W710R046
40 Adjustment and replacement

Electronic thermostat
To remove
2 1 Remove RH and LH footwell heater trims.

2 Remove 1 screw from the electrical connector

support bracket and unplug connector's.

W710R047

3 Unplug electrical connector from electronic

thermostat.

4 Remove 2 screws.

4 5 5 Remove thermostat.

To fit
Fit in reverse order.

3 4

W710R048
 Adjustment and replacement 41

Scuttle air intake filter

To remove
1 Remove wiper arm.

3 2 Remove scuttle grill.

3 3 Remove 2 screws and release plastic cover

over intake filter.

W710R049

4 Lift out filter.

To fit
Fit inr reverse order.

W710R050
42 Adjustment and replacement

Evaporator sensor
To remove
1 Remove LH footwell heater trim.

1
W710R051

2 Unclip sensor from casing.

3 Unplug connector and remove sensor.

3 To fit
Fit in reverse order.

W710R052
 Adjustment and replacement 43

Air conditioning compressor relay

To remove
1 Remove 3 screws for fascia LH lower closing

panel.

W710R053

2 Remove 3 nuts and 1 screw, drop down the

relay bracket to expose relays.

W710R054

3 Remove compressor relay.

11 1 To fit
Fit in reverse order.

10 2

9 3

8 4

7 5 6

W710R055
44 Adjustment and replacement

Blower relay
To remove
1 Remove 3 screws for fascia LH lower closing

panel.

W710R056

2 Remove 3 nuts and 1 screw, drop down the

relay bracket to expose relays.

W710R057

3 Remove blower relay.

11 1 To fit
Fit in reverse order.

10 2

9 3

8 4

7 5 6

W710R058