Retrofit Procedures

Retrofit procedure,
A/C System with Zexel compressor

- Discharge and capture refrigerant R-12 using Kent Moore ACR3 or equivalent.
- Evacuate system to remove any contaminants.
- Replace pressure relief valve.





Note:
^ Compressor removal may be necessary if pressure relief valve is not accessable as installed.

- Remove pressure relief valve -A- and replace with valve and 0-ring supplied in retrofit kit. Tightening torque: 10 Nm (7 ft lbs).

Note:
^ Lubricate lightly with PAG refrigerant oil before installing.

- If compressor is removed to replace valve, also 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 PAG refrigerant oil.

Note:
^ Only small amounts of refrigerant oil are present in installed, operational Zexel compressors. Unless access to pressure relief valves is necessary, It is not necessary to remove compressors to drain the oil.

- Reinstall compressor (if removed).
- 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, see refrigerant capacity table.
- 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 the 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.