Retrofit Procedures
Retrofit procedure, A/C System with Nippondensocompressor
- Discharge and capture refrigerant R-12 using Kent Moore ACR3 or equivalent.
- Evacuate system to remove any contaminants.
- Remove compressor.
- Drain and measure amount of existing refrigerant oil from high and low service ports (rotating compressor via the clutch will aid draining).
- Replace shaft seals (if necessary*).
- Replace manifold seals (if necessary*).
* Compressors beginning with the following manufacturer code have shaft and manifold seals which are R-134a compatible. These compressors do not need updating:
- 1605 and higher
2893 " "
3901 " "
Refer to manufacturer code location -A-.
On these units, only change refrigerant oil to PAG type.
If seal replacement is not necessary, proceed as follows:
- Fill with same amount of PAG refrigerant oil measured when draining.
Note:
^ If amount of oil drained from compressor exceeds 80 cc (2.7 fl oz), fill compressor with 80 cc (2.7 ft oz) PAG oil and fill the remaining quantity via the replacement accumulator.
- Reinstall compressor.
- Install new O-rings on compressor suction and discharge hose fittings.
- Remove accumulator.
- Clean outside of accumulator if dirty.
- Weigh the removed accumulator.
- Fill new accumulator with PAG refrigerant oil until the weight of the original accumulator is achieved.
- Install accumulator (use new O-rings).
- Replace restrictor. (use new O-rings).
- Identify and install correct R-134a adapters (from Kit Part No. 357 820 794) to service valve (5).
Low pressure service valve -1- (Blue), 7/16" connection
High pressure service valve -2- (Red), 3/8" connection or 7/16"connection
- Evacuate system for a minimum of 45 minutes using Kent Moore ACR4 or equivalent.
- Charge system with refrigerant R-134a.
- Turn compressor by hand via magnetic clutch approximately. 10 rotations.
- Perform quality check and leak test
- Install new R-134a warning label, Part No. 8A0 010 132, in place of existing R-12 warning label on front crossmember or radiator cover.
Note:
^ R-134a warning label Part No. 8A0 010 132 lists three R-134a fill capacities. Cross out fill amounts not applicable to retrofitted vehicle using a waterproof marker.
- Apply new R-134a warning label, Part No. 8A0 010 132 E, to visible location on compressor housing.
- Affix new R-134a warning label, Part No. 8A0 010 132 G, to first page of the vehicle Maintenance Booklet.
Nippondenso compressor shaft seals, replacing
Note:
^ Prepare a clean work area to ensure against seal leakage after installation.
Note:
Coat lightly with PAG refrigerant oil before installing.
Fig.1 Flange Seal (with collector ring-counter support),
removing and installing
- Remove clutch assembly,
Repair Manual, Air Conditioning, Repair Group 87.
- Insert puller -A- in groove -D- of flange seal.
- Tighten sleeve by pushing in the tension ring -B-.
- Remove shaft seal by turning screw -C-.
Note:
^ Lubricate lightly with PAG refrigerant oil before installing.
Fig. 2 Shaft seal (with collector ring)
removing and installing
- Insert puller -A- in shaft seal -B-, remove shaft seal.
- Check shaft for dirt and clean if necessary.
- Check shaft of compressor and groove -C-, if sharp edges or burrs are present, remove and clean shaft.
Note:
^ Lubricate lightly with PAG refrigerant oil before installing.
- Install clutch assembly and adjust gap.
Nippondenso compressor manifold seals, replacing
Notes:
^ Nippondenso compressors have two different types of suction/discharge manifold assemblies;
^ manifold without pre-chamber
^ manifold with pre-chamber
^ Diagram shows manifold without pre-chamber.
- Remove 4 bolts -A- Tightening torque 20 Nm (15 ft lb).
- Clean surfaces -B-, remove all traces of refrigerant oil.
- Replace O-rings -C-.
Note:
^ Lubricate lightly with PAG refrigerant oil before installing.
Note:
^ Diagram shows manifold with pre-chamber:
- Remove bolts -G-
Tightening torque 20 Nm (15 ft lb).
- Remove manifold -B- from pre-chamber -A-.
- Clean surface -C-, remove all traces of refrigerant oil.
- Replace formed seal -D- and O-rings -E-.
Note:
^ Alignment pin -F-, check for correct fit.