FAULT COMPLAINED OF

Climate control system not working.

TECHNICAL CAUSE

Loss of coolant from the joint of the condenser delivery and return pipes

OPERATIONS IN PRODUCTION

Starting from the chassis number below, the fitting of new, improved seals is guaranteed on the condenser delivery and return pipes.

IPLEMENTATION OF MODIFICATION

Version	Factory	Line	Chassis No.	Organisation No.
All models in question	Mirafiori	-	1134578	133078

OPERATIONS IN NETWORK

Network behaviour standards towards the Customer

-Once the customer's claimed fault is confirmed, reassure the Customer that will be solved by replacing the condenser and compressor supply and return pipe seals with improved ones.-After the operation, show the Customer what has been done and make sure he is satisfied.

Service Solution

Once the customer's claimed fault is confirmed, depending on the engines, replace the condenser and compressor delivery and return pipe seals with improved ones, according to the Operating Cycle below.

OPERATION CYCLE

Follow the recommended safety instructions (see 5040 - Introduction) of the Service Manual.

For all engine types

Replace the condenser delivery and return pipe seals as below described.

-Position the car on a lift.-Drain coolant, with reference to Op. 0010T84 of the Service Manual.-Remove the front bumper, with reference to Op. 7210E10 of the Service Manual.-Release from the mounting clips (1 - Fig. 1) the condenser delivery and return pipes (4);-Undo the nut (2) fixing the securing plate (3) to the condenser delivery and return pipes (5), then disconnect the upper pipe and the plate, followed by the lower pipe, with reference to Op. 5040A of the Service Manual.

Fig. 1

-Replace the seals of the condenser delivery and return pipes with new seals (1) no. 10877980 (dia. 1/2'') and (2) no. 10877887 (dia. 3/8''), from the Spare Parts Dpt.

Fig. 2

-Refit the pipe (3) on the compressor and tighten the fixing screw to the prescribed torque of 1.8 ÷ 2.2 daNm.

Depending on the engine type, replace the compressor delivery and return pipe seals as below described.

For 1.4 16V 95 HP (EURO 5) - 1.3 MultiJet engines

-Remove the under-engine guard/protection, with reference to Op. 7055B54 of the Service Manual.-Remove the engine compartment dust cover in the right front wheel housing, with reference to Op. 7055B66 of the Service Manual.-Press the tabs (1 - Fig. 3) and disconnect the quick connectors (2) from the tandem pipe.-Undo the screw (3) securing the tandem pipe (5) mounting bracket (4).-Undo the screw (6) and disconnect the connector (7) for the tandem pipe to the compressor (8).-Replace the seals of the tandem pipe (5) with new seals (9) no. 10877980 (dia. 1/2'') and (10) no. 10878180 (dia. 3/4''), from the Spare Parts Dpt.

Fig. 3

-Refit the tandem pipe on the compressor and tighten the fixing screw to the prescribed torque of 1.8 ÷ 2.2 daNm.-Tighten the screw fixing the pipe mounting bracket.-Reconnect the quick connectors to the tandem pipe.-Refit the engine compartment dust cover in the right front wheel housing, with reference to Op. 7055B66 of the Service Manual.-Refit the under-engine guard/protection, with reference to Op. 7055B54 of the Service Manual.

For 1.6 JTD 16V engines

-Remove the under-engine guard/protection, with reference to Op. 7055B54 of the Service Manual.-Remove the engine component single drive belt, with reference to Op. 1092G10 of the Service Manual.-Remove the compressor from the air conditioning system, with reference to Op. 5040A20 of the Service Manual.

Seal the connectors that have been disconnected using suitable sealing plugs to prevent dampness and impurities from entering the system.

-Undo the fixing screw (1 - Fig. 4) and remove the tandem pipe (2) from the compressor by releasing the retainers (3).-Replace the seals of the tandem pipe (3) with new seals (4) no. 10877980 (dia. 1/2'') and (5) no. 10878180 (dia. 3/4''), from the Spare Parts Dpt.

Fig. 4

-Refit the compressor of the air conditioning system, with reference to Op. 5040A20 of the Service Manual.-Refit the engine component single drive belt, with reference to Op. 1092G10 of the Service Manual.-Refit the under-engine guard/protection, with reference to Op. 7055B54 of the Service Manual.

For all engine types

-Reinstall the front bumper, with reference to Op. 7210E10 of the Service Manual.-Remove the vehicle from the lift.-Recharge coolant, with reference to Op. 0010T84 of the Service Manual.

AVALABILITY OF PARTS

Version	Description	Part No.	Q.ty
All models in question	Special seal, 3/8''	10877887	1
All models in question	Special seal, 1/2''	10877980	2
All models in question 1.4 16V 95 HP (EURO 5) - 1.3 MultiJetv - 1.6 JTD 16V	Special seal, 3/4''	10878180	1

CLAIM REPORT DATA

Version	Operation	Part	Fault	Position	Time allowance
All models, excluding 1.4 16V 95 HP (EURO 5) - 1.3 MultiJet - 1.6 JTD 16V	5040170	1	EN	-	1.20 (*)
1.4 16V 95 HP (EURO 5) - 1.3 MultiJet	5040173	1	EN	-	1.50 (*)
1.6 JTD 16V	5040173	1	EN	-	2.30 (*)

(*) The time allowance includes seal replacement and coolant recharge in the air conditioning system.