Replacement Compressor Updating
Replacement Zexel compressor, updatingNote:
^ Two types of replacement Zexel compressors are available; R-12 and R-134a type (labeled/identified as such). The R-134a type will be the only replacement compressor available when supplies of R-12 type run out.
Only when replacement of a damaged or leaking Zexel compressor is necessary prior to system retrofit, update the replacement unit as follows:
- Obtain Zexel retrofit kit:
Part No. 4AO 298 107
- Relieve nitrogen charge in replacement compressor by carefully loosening protective caps on suction and discharge ports.
- In both cases (R-12 or P-134a type), replace pressure relief valve.
Note:
R-12 type replacement compressors are factory filled with R-12 compatible compressor oil which must be drained.
- Drain and measure amount of existing refrigerant oil via oil drain plug (rotating compressor via the clutch will speed draining).
- Fill with same amount of FAG refrigerant oil.
- If amount of oil drained exceeds 80 cc (2.7 fl oz), fill compressor with 80 cc (2.7 fl oz) FAG oil and the remaining quantity via the replacement accumulator.
- Proceed with system retrofit.
Notes:
^ R-134a type replacement compressors are factory filled with R-134a compatible compressor oil. This oil does not require changing.
^ R134a type replacement compressors require the suction/discharge manifold from the original (R-12) compressor to be removed and installed on the replacement unit.
R134a Zexel replacement compressor, modification
^ (applies only when replacing damaged or leaking R-12 Zexel compressor with R-134a Zexel compressor)
Notes:
^ Prior to system retrofit, R-134a type replacement compressors require interchanging the manifold plates from the existing compressor to the new compressor:
^ If equipped, angled suction/discharge manifold adaptors must be interchanged
- Prepare a clean work area to ensure against seal leakage after installation.
- Relieve nitrogen charge in replacement compressor by carefully loosening protective caps on suction and discharge ports.
- Remove pressure relief valve from manifold plate -B- of existing R-12 compressor and replacement R-134a compressor.
- Remove bolts -A- from both the existing compressor and new compressor.
Tightening torque 20 Nm (15 ft lbs).
- Remove manifold plate -B- from both compressors.
- Clean surface -C- on R-134a replacement compressor; remove all traces of refrigerant oil.
- Install manifold plate from existing R-12 compressor on new R134a replacement compressor.
- Install new pressure relief valve from retrofit kit.
Notes:
^ Check for correct alignment of pins -E- and spring washer -D- (for suction pressure control).
^ R-134a type replacement compressors are factory filled with R-134a compatible compressor oil. This oil does not need to be changed
Note:
^ Existing R-12 compressors equipped with an angled suction/discharge adaptor only require interchanging of the angled adaptor to the replacement R-134a compressor and the installation of the pressure relief valve. Manifold interchange is not necessary with this configuration.
- Remove bolts -D- from existing compressor
Tightening torque 20 Nm (15 ft lbs).
- Remove manifold adaptor -A- and transfer to new R-134a replacement compressor
- Replace pressure relief valve -B-.
- O-rings -C- from R-134a replacement compressor may be used (available in kit, Part No. 4A0 298 013 AA if required).
- Proceed with system retrofit.