Roxor 1203AUA00041N User manual

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 1 of 20
W O R K I N S T R U C T I O N O V E R V I E W
lDO NOT ATTEMPT THIS PROCEDURE IF YOU DO NOT HAVE
PROPER TOOLS, TRAINING, AND FACILITIES.
lNever consider using a two-post lift that is not certified
according to ANSI/ALI ALCTV-2011 or ANSI/UL 201.
(autolift.org)
lRead and follow all instructions provided when installing this
product. Failure to do so may result in placing occupants at
risk of serious injury or death.
lTo protect bystanders and the service technician(s), shut
vehicle off, remove the Ignition Key and secure vehicle to
prevent unintended movement.
lNever operate the vehicle in excess of manufacturer’s
specifications.
lDo not remove any of the A/C Component Caps until you are
ready to connect the Pressure Lines.
lIf installing the Vintage HVACAssembly on a vehicle
equipped with an Manual Transmission, it is required that you
also install a Fan Shroud over the cooling fan with:
oFan Shroud - Part Number 0304FAB00771N
lRefer to Fan Shroud.
lInstallation of Vintage HVAC will require specific components
and holes to be drilled into the vehicle using the provided
Templates.
lFor Vintage HVAC kits ShippedON or BEFORE 9/1/2019,
Paper Templates should have been supplied in your kit.
Contact the ROXOR Customer Care Line if templates were not
provided in your kit. Paper templates will be provided on
request.
lFor Vintage HVACKits Shipped AFTER9/1/2019, Templates
are located at the end of the Work Instructions for print on
8.5 x 11 paper. Must click "Actual Size" in Print Settings.
Verify the square on each template is 1" x 1" for accuracy of
print.
T O O L S R E Q U I R E D
o13 mm Socket
o19 mm Socket
o6 mm Allen Wrench
o9/16 mm Wrench
o19 mm Wrench
o22 mm Wrench
o25 mm Wrench
o27 mm Wrench
o32 mm Wrench
oSocket Wrench
oHose Cutters
oStep Bit Drill Bits
oTemperature Gauge
o19 mm Crows Foot
o27 mm Crows Foot
o32 mm Crows Foot
oHose Clamps
oSocket Extension
oSwivel Socket Extension
oProtective Eye-wear
oPry Bars (Large)
oPry Bar (Thin)
oTorque Wrench (Nm)
oR134A Recovery, Recycling,
and Recharging Machine
T O R Q U E S P E C I F I C A T I O N
Tighten each fastener to the torque specification below:
lM6 Fasteners – 10 N•m (±1 N•m)
lM8 Fasteners – 23.5 N•m (±3.5 N•m)
lM10 Fasteners – 43 N•m (±7 N•m)
lM12 Fasteners – 90 N•m (±10 N•m)
lLiquid Line – 17 N•m (±3 N•m)
lDischarge Line – 24 N•m (±3 N•m)
lSuction Line – 34 N•m (±7 N•m)
lPressure Switch - Receiver Drier – 16 N•m (±2 N•m)
C O M P O N EN T T A B L E
Components Description Qty
HVAC Assembly
Left Bracket pre-installed for Manual
Transmission Vehicles-See Drill Holes
Section
P/N-1203CUA00091N
1
1/2" Drain Hose (18")
For EVAP Drain Hole
1
AC Compressor Kit - Includes Compressor,
Brackets and Fasteners
P/N-1203AUA00071N
1
AC Compressor Adjuster Bracket w/ Spacers
- Included within AC Compressor Kit
P/N-1203AUA00071N
1

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 2 of 20
Components Description Qty
AC Compressor Bracket - Lower Rear -
Included within AC Compressor Kit
P/N-1203AUA00071N
1
AC Compressor Bracket - Lower Forward -
Included within AC Compressor Kit
P/N-1203AUA00071N
1
AC Compressor Ground Cable
P/N-1801EA0100N
1
AC Receiver Drier Kit
Includes Bracket and Pressure Switch
1
AC Condenser Assembly 1
Isolators for Condenser
Included in AC Condenser Assembly
2
Keepers for Isolators
Included in Condenser Kit
2
Brackets for Condenser
Included in Condenser Kit
2
AC Suction Line Cork Tape 1
AC Liquid Line
Drier to Condenser (Lower Condenser Port)
1
AC Discharge Line - AC
Compressor to Condenser (Upper
Condenser Port)
1
AC Suction Line
Firewall to Compressor
1
AC Suction Line
Evaporator to Firewall (Left)
1
AC Liquid Line
Evaporator to Firewall (Right)
1
AC Liquid Line
Firewall to Receiver/ Drier
1
Components Description Qty
V Belt 1
Grommet - Dash Panel
(Reused From Firewall)
2
Heater Core Shutoff Valve 1
5/8" Heater Hose
Heater Core to Heater Core Shutoff Valve
1
Connector Heater
EGR Return
P/N 1202DUA00161N
1
Cable Tie Straps - 305 Long
To Secure Wire Loom
P/N 0000AUA00461N
1
Cable Tie Strap 165 W Xmas Tree
Heater Hose to LH Dash Bracket
To secure Coolant Heater Core Hoses to
HVACAssembly
P/N 0000AUA00451N
1
CAP - NON DEFROST
P/N 1203ZUA00611N
2
M8X45 Combination Bolts LP w/ Washers -
M8X1.25X45X8.8.2
Battery Brace Bolts
P/N SF0103151
2
M6X16 Hex Flange Bolts
Upper Condenser Bracket to Radiator Guard
Assembly
P/N 0000AUA00711N
2
M8X25 Hex Flange Bolts
Compressor Adjuster Pivot Bracket/ Lower
Front Compressor Bracket to Compressor
P/N 0000AUA00941N
2
M12X35 Hex Bolt HD (M12X1.5X35)
Motor Mount for Lower Rear Compressor
Bracket to Engine Mount
P/N 0000AUA01171N
1
M8X50 Hex Flange Bolt (M8X1.25X50X10.9)
Lower Rear Compressor Bracket to
Compressor
P/N 0000AUA01481N
1

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 3 of 20
Components Description Qty
M8X81Hex Hex Flange Bolt (M Point)
Adjuster Bracket to Front Cover Upper Bolt
P/N 0000AUA02081N
1
M10X40 Hex Flange Bolt
Adjuster Bracket to Front Cover Lower Bolt
P/N 0000AUA01321N
1
M10X25 Hex Flange Bolts
Lower Front Compressor Bracket to Engine
Block
P/N 0000AUA01591N
2
BOLT M8X1.25X25 BUTTON HD 6 LOBED
P/N 0000AUA02021N
2
M6X1X19 Torx Screws-Large Crown WA -
HVAC Assembly to IP
P/N 0000AUA00061N
6
M12 Lock Washer
(Reused from Motor Mount Bolt)
1
M8 Spring Lock Washers
P/N 6508212
3
M12 Flat Washer
For Motor Mount Bolt
P/N 0000AUA01181N
1
M8X16 Plain Washers - M8X16.1.5XZN5
RH HVAC to Brace Lower Rear Compressor
Bracket to Compressor
P/N SF401012
3
M6 Flat Washer
Lower Condenser Bracket to Radiator Guard
Assembly
P/N 0000AUA01531N
2
M6 U Nuts
(2) HVACAssembly to IP
(2) Condenser to Radiator Box
P/N 0000AUA00411N
7
M6X9 Flange Nylon Hex Nut - M6X1X9X8
(2) HVAC Assembly to Dash Left Bracket
(2) Lower Condenser Bracket to Radiator
Guard Assembly
P/N SF0315004
5
M8 Hex Nuts - 1.25
HVAC to Dash/RR Compressor Bracket
P/N SF0301009
5
Components Description Qty
M6X6.5 Flange Hex Nut (M6X1X6.5X8)
12V HVAC Power to Battery
P/N 0000AUA01631N #200
1
AC Refrigerant Caution Label
P/N 0003AUA00921N
1
P R EP A R A TI O N P R O C E D U R E
1. Loosen (2) M6 nuts for battery positive and negative cables.
Set both cables aside.
2. Remove (2) M6 nuts on battery retainer. Remove battery
retainer and save all for reuse. Cover battery terminals.
3. Place a catch below radiator and drain coolant from lower
right drain port.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 4 of 20
D I SA SSE M B L Y P R O C ED U R E
1. Remove (2) 8 mm Hex Head Bolts from Fuse Block and
Discard bolts and bracket.
2. Remove Wire Harness Clip and (2) 13 mm Hex Head Bolts
from the Battery Brace. Replace with (2) M8X45 Combination
Bolt and (2) M8X6.5 Hex Nut. Torque to Specification. Push
Wire Harness Clip back through.
3. Remove Steering Column Cover, (3) 13 mm Bolts, (9) M6 T30
Torx screws, Upper (2) M6 T30 Torx Screws of Grab Handle
and (3) Switch Connectors, Speedometer Connector, Ignition
Switch Connector and Aux Power Outlet Connector and
remove the Instrument Panel.
4. Remove (3) M6 nuts, Connector and remove Left Headlight.
Repeat for opposite side.
5. Lift the Vehicle and remove (1) T30 Torx Screw from Grill.
Starting from Front Left, slightly pull back Grill and carefully
pry out each Clip and remove Grill.
6. Remove vacuum and breather hoses. Loosen lower (1) bolt
for snorkel tube and remove air filter housing with snorkel
tube.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 5 of 20
7. Remove (2) M8 Bolts, upper bracket, air filter housing and
lower bracket.
8. Using 10 mm wrench, loosen bolt and remove accessory belt
from alternator.
R E Q U I R E D A C C E S S O R Y I N S TA L L A T I O N
1. It is now time to install any required installations. See
overview for additional information and part numbers.
oPause this installation and proceed to requiredWork
Instructions for Fan Shroud. Once finished, return here to
continue with Vintage HVACinstallation.
2. Install Fan Shroud if Manual Transmission. Refer to Fan
Shroud.
D R I LL H O L ES P R O C ED U R E
1. Templates have been designed for accurate hole placements.
All Templates can be found at the end of the Work
Instructions in PDFform.
oFor Vintage HVAC kits ShippedON or BEFORE 9/1/2019,
Paper Templates should have been supplied in your kit.
oFor Vintage HVACKits ShippedAFTER9/1/2019,
Templates are located at the end of the Work Instructions
for print on 8.5 x 11 paper.
oMust click "Actual Size" in print settings
oVerify squares on templates are 1" x 1" for print accuracy,
before trimming.
oCut out to the alignment arrow edges
oCut out cross-hatched areas
2. Before drilling any holes for Vintage HVACInstallation, identify
which pre-drilled holes on bulk head you have. You will either
have 4 or 6 Large holes pre-drilled.
oBulk head's with 6 holes, the holes for Left HVACunit
bracket are pre-drilled. If 4 hole, you need to drill these
holes in the next step.
oThis only affects the step below. If you only have 4 Large
holes pre-drilled, proceed to the next step. If you have 6
large holes, skip the next step.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 6 of 20
3. If 6 hole, skip this step. Using magnets or tape, fasten the
Template on Firewall and drill (2) 19/64" holes for the HVAC
Assembly mounting bolts. Accessory Pass-through Holes.
oTo prevent premature rusting of the body, use a Deburring
Tool and apply paint or other suitable rust inhibitor to all
holes drilled for this installation.
oPaint the raw steel edges to prevent corrosion, allow to
dry before installing grommets.
4. Using magnets or tape, fasten the Templates at outer sides of
Battery Braces. Using a Step Drill Bit, Drill a 15/16" hole for
Suction Line on left and 11/16" hole for Liquid Line on right of
Firewall.
To prevent premature rusting of the body,
use a Deburring Tool and apply paint or other suitable rust
inhibitor to all holes drilled for this installation.
5. Using magnets or tape, fasten the Templates on right side of
the Battery Brace. Using a Step Drill Bit, Drill a 45/64" for the
Condenser Drain Line on the Firewall.
To prevent premature rusting of the body,
use a Deburring Tool and apply paint or other suitable rust
inhibitor to all holes drilled for this installation.
6. Using magnets or tape, fasten the Template to the Right
Front Clip Brace and drill (2) 1/8" holes for the Receiver/ Drier
Bracket.
To prevent premature rusting of the body,
use a Deburring Tool and apply paint or other suitable rust
inhibitor to all holes drilled for this installation.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 7 of 20
7. Using magnets or tape, fasten Template to the Right Front
Fender and drill (1) 5/16" holes for AC Liquid Line.
To prevent premature rusting of the body,
use a Deburring Tool and apply paint or other suitable rust
inhibitor to all holes drilled for this installation.
8. Using magnets or tape, fasten the Template onto the Radiator
Housing and drill (2) 19/64" holes for Condenser.
9. Using magnets or tape, fasten the Templates to the Radiator
Housing. Using a Step Drill Bit, drill a 1 1/2" hole for (Upper)
Discharge Line to the Compressor and 1 1/2" hole for (Lower)
Liquid Line to the Receiver Drier through the Radiator Box.
To prevent premature rusting of the body,
use a Deburring Tool and apply paint or other suitable rust
inhibitor to all holes drilled for this installation.
I N S T A L L A T I O N P R O C E D U R E
1. When installing A/C refrigerant lines, be sure A/C lines are:
oLevel to port
oO-rings are lightly lubricated and flush against the ridge
on A/C line
oA/C Lines are fully inserted before attempting to tighten
oHand-thread to begin tightening
2. Before installing HVACassembly into vehicle, install A/C lines
to evaporator ports in orientation shown below:
oUsing a 9/16" wrench to counter-hold the brass outlet and
3/4" wrench to tighten A/C liquid line (lower).
oUsing a 7/8" wrench to counter-hold the brass outlet and
1 1/16" wrench to tighten A/C suction line (upper).
oTorque lines to specifications.
oAll A/C Refrigerant Lines and Component Outlets are
sealed for integrity. Sealing caps should not be removed
for extended periods of time before installation. Be sure
when opening the sealing caps, there is an audible release
of air.
oBe sure the O-rings do not remain within the sealing caps.
oBe sure the A/C Lines are level and fully inserted before
attempting to tighten.
oBefore installing any A/C Refrigerant Lines, be sure to
lightly lubricate the O-rings on each line.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 8 of 20
3. Install cork tape to suction line as show below. This is to
prevent condensation leaking down.
4. Install the left side of the HVAC assembly guiding the (2) weld
studs into drilled holes on bulkhead. Using 10 mm socket
and (2) M6X9 flange nylon hex nuts, finger tighten.
A second technician may be necessary to
assist in installation of HVACunit.
5. Mount Right Side of HVAC Assembly onto Battery Brace
against previously installed Nuts. Using 13 mm Deep Well
Socket, install (2) M8X6.5 Hex Nut, (2) M8XZN5 Plain Washer
and (2) M8 Spring Lock Washers (The double nut assembly
will serve for tightening HVACNuts without having to counter
hold Battery Brace Bolts). Torque all HVAC Assembly
Fasteners to specification.
6. Install both Liquid Line and Suction Line through Fire Wall
and torque (a second Technician will be necessary).
oFor Liquid Line, Counter-hold using 1" Wrench Inside and
1" Socket Outside to Torque Nut
oFor Suction Line, Counter-hold using 1 1/8" Wrench Inside
and 1 1/4" Socket Outside the Bulkhead to tighten Nut
oTorque both Nuts to Specification

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 9 of 20
7. Remove sealing caps from HVACheater core pipes. Cut (1)
5/8" heater hose in half and install to pipes. Fasten hoses
using (1) zip tie and feed both out through right bulkhead
holes using (2) new grommets.
8. Using Hose Clamp Pliers, remove EGR Coolant Return Hose
and cut just below the bend (Yellow Line). On the trimmed
end, install (1) Spiral Hose Clamp with (1) Connector Heater,
then install Coupled end back to main hose.
9. Remove the Hose from the Hose Mount. Using Hose Cutters,
cut both sides of the Coolant Hose just below bend as
shown.
10. Install EGR Coolant Return Hoses with (2) Spiral Hose Clamps
to Coolant Shutoff Valve. Trim 5/8" Heater Hoses from Heater
Core to length using Hose Cutters. Using (2) Spiral Hose
Clamps, install both 5/8" Heater Hoses to Coolant Shut Off
Valve. Reinstall EGR Coolant Return line with Hose Clamp and
check that all Spiral Hose Clamps tightened.
11. Fully close the push pull cable knob at HVAC control panel,
and fully close shutoff valve. Install push pull cable using
supplied screw with clamp and tighten. Place spiraled end of
cable on shutoff valve arm using supplied keeper as shown.
12. Using 19 mm socket, remove (1) motor mount bolt. discard
bolt and save (1) lock washer for reuse.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Vintage HVAC Assembly
Vintage HVAC Kit (P/N - 1203AUA00041N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 10 of 20
13. Install lower rear compressor bracket with (1) M12X35 hex
bolt and (1) M12 flat washer and (1) M12 lock washer (reused
from previous step) using 19 mm socket.
14. Install the lower front compressor bracket with (2) M10X25
hex flange bolt using 15 mm socket.
15. Using 12 mm socket, remove the timing cover bolt and
discard.
16. Install the Upper Compressor Bracket using 13 mm Socket
and (1) M8X80 Hex Flange Bolt with (1) Spacer Upper. Using
15 mm Socket, Install (1) M10X40 Hex Flange Bolt with (1)
Spacer Lower.
17. Remove the compressor sealing plate nuts using 13 mm
socket. Discard plate and nuts. Install suction and discharge
fittings using T30 torx and new (2) M8 torx bolts. Install
suitable sealing caps to protect compressor from moisture
and debris.
All A/C Refrigerant Lines and
Component Outlets are sealed for system integrity. Sealing
caps should not be removed for extended periods of time
before installation. Be sure when opening the sealing caps,
there is an audible release of air.
18. Install the Compressor Using 13 mm Socket to tighten (1)
M8X50 Hex Flange Bolt, Compressor Ground Cable, (1)
M8X6.5 Hex Nut, (1) M8XZN5 Plain Washer, (1) M8 Spring
Lock Washer (arrow left) and (1) M8X25 Hex Flange Bolt
(arrow right) at Lower Compressor. Torque to specifications.
Compressor Ground Cable will be routed
at a later step.