R-1234yf A/C Update Alan McAvoy [email protected] 1 Why HFO-1234yf? Meet the directive for a refrigerant with a Global Warming Potential (GWP) of less than 150 1979 2003 Why R-1234yf? • 2016 EPA mandate for corporate fleet average <250 g/mile of CO2 • Lower GWP refrigerant, A/C system leak reduction & A/C efficiency improvements provide credits for the manufacturer towards the CO2 requirement 3 types of A/C credits available: Direct Credits 1. R-1234yf alternative refrigerant (up to 15.8 g/mile of credit per vehicle) 2. Refrigerant leak reduction on current refrigerant (up to 7.2 g/mile of credit per vehicle) Indirect Credits 3. System efficiency improvements (up to 5.7 g/mile of credit per vehicle) R-1234yf Developed by DuPont & Honeywell • Solstice™yf Refrigerant (R-1234yf) See www.1234facts.com • Similar procedures & processes compared to R134a • Pressure & temperature relationship similar to R134a 2015 FCA NAFTA R-1234yf Phase in Sales Code - XFC = Built with R-1234yf A/C Refrigerant • Alfa Romeo 4C • Chrysler 200 (UF) • FIAT 500 & 500L (FF/BF) • Chrysler 300 (LX) • Ram 1500 (DS) • Dodge Durango (WD) • Jeep Grand Cherokee (WK) • Dodge Challenger (LA) • Jeep Wrangler (JK) • Dodge Charger (LD) • Jeep Cherokee (KL) • Dodge Dart (PF) Calendar year Body Code 2013 2014 2015 DS R-1234yf FF/BF/4C R-1234yf JC JK R-1234yf KL R-1234yf LX/LD/LA R-1234yf RT PF R-1234yf UF R-1234yf WK/WD R-1234yf FCA 2015 R-1234yf A/C Compressors (NAFTA) • Ram 1500 / Jeep Cherokee & Wrangler Wrangler / Chrysler 200 & 300 / Dodge Challenger & Charger • Denso 7SBH17C Variable Displacement Compressor • Dodge Dart • 1.4L Turbo = Delphi Fixed Displacement • 2.0L / 2.4L MultiAir - Denso 7BH17C Variable Displacement Compressor • Jeep Grand Cherokee / Dodge Durango • FIAT 500 / 500L • Alfa Romeo 4C • Delphi Variable Displacement Clutch & Coil Compressor R-1234yf A/C Refrigerant Mopar only offers 10 lb. disposable cylinders of R-1234yf to our dealers • P/N 68224028AA is priced per oz. with an MSQ (minimum sales quantity) of 160 (160 oz. = 10 lbs.) • Part quantity: Dealers are to bill how much refrigerant is used for the repair, which is the difference between the recovered amount and the charged amount as shown on the print out from the A/C machine • Current list price is $9.73 per oz. or $1,556.80 per 10 lb. cylinder R-1234yf System Modifications R-1234yf Underhood Label R-1234yf Compressor Oil Mopar PAG ND-12 Compressor Oil p/n 68224150AA • R-1234yf vehicles require new compressor oils • DO NOT use R134a PAG oil in R-1234yf systems as it lacks the acid reducer required for R-1234yf systems • Denso Compressors use PAG ND- 12 oil which is backwards compatible with some R134a systems (Replaces Denso ND8 oil) • Delphi R-1234yf Compressors use p/n 68232939AA (PSD-1) Oil Typical Refrigerant Oil Capacities CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. Same Compressor Oil Drain Procedure as other Chrysler Vehicles • Drain all of the refrigerant oil from the old A/C compressor • Drain all of the refrigerant oil from the new A/C compressor • Refill the new A/C compressor with the same amount of refrigerant oil drained out of the old compressor • Use only clean refrigerant oil of the type specified for the A/C compressor in the vehicle Denso 7SBH17C R-1234yf Compressor High Pressure Relief Valve A/C Clutch & Coil Control Solenoid Denso 7SBH17C Variable Displacement Compressor Denso 7SBH17C R-1234yf Compressor Pulley A/C Clutch Control Solenoid Swashplate Pistons Integral Control Solenoid to reduce or increase the stroke of the pistons by adjusting the angle of the swashplate Denso 7SBH17C R-1234yf Compressor • A/C Clutch Relay in PDC controlled by the PCM • Control Solenoid is controlled by the HVAC Module • HVAC Module calculates compressor displacement based on A/C load & demand • Monitored inputs include Vehicle Speed, High side pressure, Engine RPM, Evap temp, In Car temp, Accelerator position, Ambient temp, Humidity & A/C request. • HVAC module sends a 12 volt PWM signal to the Control Solenoid to increase or decrease refrigerant flow • Controls the angle of the swashplate • Regulates the pressure exerted on the rear of the pistons. Increased pressure reduces the length of the stroke • With low A/C demand, swashplate is adjusted to nearly a zero degree angle to reduce drag & improve MPG Denso 7SBH17C R-1234yf Compressor Maximum duty cycle 100% = Compressor at maximum displacement Minimum duty cycle 11% = Compressor at minimum displacement Denso 7SBH17C R-1234yf Compressor • High pressure relief valve vents refrigerant at 3445-4135 kPa (500-600 psi) • High pressure relief valve closes at 2756 kPa (400 psi) or below • PCM monitors high-side pressure through the A/C Pressure Transducer • High Pressure Cut-out above 3140 kPa (455 psi) • A/C Clutch will re-engage below 2450 kPa (355 psi) • Low Pressure Cut-out below 110 kPa (16 psi) • A/C Clutch will re-engage above 221 kPa (32 psi) Typical R-1234yf A/C Performance Test Operate the HVAC system under the following conditions • Ambient temp: 15.5°C (60°F) to 43.3°C (110°F) • Relative humidity: 20% to 90% • Engine idling at normal operating temp • No sun-load, doors & windows closed • A/C heater controls set to Recirc mode, full cool, panel mode, high blower with A/C compressor engaged. • With a scan tool, actuate the engine cooling fans to high speed • Insert a thermometer in the driver side center panel air outlet & operate the A/C system until the thermometer temp stabilizes or a minimum of five minutes • With the A/C clutch engaged, compare the panel outlet air temp, ambient temp & relative humidity to the Maximum Panel Outlet Temperature chart. Typical R-1234yf A/C Performance Test Similar to Chrysler R134a Performance Tests – See Service Info for specific operating parameters & testing conditions R-1234yf Evaporator Evaporator fins A/C evaporator tubes New high efficiency Tapping block & O-ring seals evaporators must meet SAE J2842 R-1234yf Evaporator Label Tech must Dispose of See service Cautions be certified properly procedures R-1234yf evaporators must comply with the new J2842 SAE design and certification safety standard. This new safety standard addresses the flammability risk associated with R-1234yf refrigerant, high pressures, and possible poisoning in the event of a release of refrigerant in the passenger compartment. J2842 guidelines state that a faulty evaporator cannot be replaced with a used evaporator from another vehicle or from a salvage yard. New evaporators must meet J2842 standards and label requirements. Cabin Air Filter Cabin Air Filters are now standard on most vehicles Replace every 2 years or 20,000 miles R-1234yf Expansion Valve Recalibrated for the thermodynamic properties of R-1234yf R-1234yf Expansion Valve • Thermostatic expansion valve (TXV) design • Aluminum H-valve type body, with integral thermal sensor • Similar test procedure to Chrysler R134a Systems • See Service Info for specific operating conditions & test procedure • Freeze the A/C expansion valve control head for 30 seconds using liquid CO² • Suction pressure should drop by at least 69 kPa (10 psi) • Allow expansion valve control head to thaw. Suction pressure should stabilize at 207 kPa to H-Valve 345 kPa (30 psi to 50 psi) R-1234yf Condenser & Receiver Drier Receiver A/C Lines Condenser Drier • Tapping blocks for A/C refrigerant lines • Integral Receiver Drier • Condenser & Receiver Drier are not serviced separately & currently replaced as an assembly Active Grille Shutters (AGS) The AGS system is controlled by the powertrain control module (PCM) over a dedicated network LIN bus. When the ambient air and engine coolant temperatures are below a specified threshold, airflow across the radiator is not required. When airflow across the radiator is not required and vehicle speeds reach a calibrated threshold, the PCM will command the shutter vanes to close. Integrated IHX Assembly Integrated IHX Assembly R-1234yf A/C Lines – Integrated IHX From Evap To Compressor To Evap From Cond Hose in Hose Internal Heat Exchanger Line (IHX) • Co-axial design with the liquid line to the evaporator on the outside & the suction line to the compressor on the inside. • Improves A/C efficiency & performance • Also used on some R134a Chrysler vehicles R-1234yf New Service Ports • Larger diameter R-1234yf ports to prevent cross- contamination • Higher collar & shoulder on High-Side port prevents R134a couplers from attaching to the R-1234yf service ports R-1234yf New Service Caps • R-1234yf service caps are gray in color • R134a service caps are black in color Jeep Renegade R-1234yf A/C System A portion of the high- pressure line, including the high-pressure port, is made of plastic R-1234yf Recovery/Recycle/Recharge Equipment • Must meet SAE & ISO standards - SAE J2843 • Integrated Refrigerant Identifier Robinair R-1234yf A/C Machine mopar.snapon.com Robinair Model 10500 shipped to all FIAT Chrysler Dealers as an essential tool (similar to the Robinair AC1234-6) Robinair R-1234yf A/C Machine DLC Connector Identifier & Filter ISV Filter Oil Drain Robinair R-1234yf A/C Machine R-1234yf A/C machine print out provides: • Date & Time • Ambient Temp & Humidity • High & Low Side Pressures • Amount of R-1234yf Recovered • Amount of R-1234yf Charged • Purity of refrigerant & % of air • Vehicle Identification Number • Warranty code Adding Refrigerant Oil The Robinair machine meets oil cross-contamination requirements for high-voltage systems • Empty the oil drain bottle before starting a recovery • Oil collected drains into the graduated oil drain bottle • Remove the bottle and measure oil • Amount of oil removed from the A/C system is the amount of new oil to be charged into the A/C system after evacuation is complete • Add the recommended new oil to replace the oil removed during the recycling process • A standalone R-1234yf Oil Injector is recommended to add oil.