Operation CHARM: Car repair manuals for everyone.

Components and Replacing

A/C REFRIGERANT SYSTEM (R-134A) COMPONENTS, REPLACING

^ All repairs for A/C, heating and ventilation components that DO NOT affect the refrigerant system can be performed as described for R-12 equipped vehicles.

^ Replacement A/C compressors, evaporators and condensers supplied by the Parts Dept. are filled with nitrogen. If gas does not escape when component is first opened, the component may be faulty, do not install.

^ Install new replacement accumulator immediately after opening to prevent moisture contamination of desiccant.

^ Always plug open refrigerant line connections to prevent dirt and moisture contamination.

^ Always replace restrictor whenever system is discharged due to a leaking component.

^ Dispose of contaminated refrigerant (PAG) oil following laws governing hazardous waste disposal. Do not combine PAG oil with any other old oils such as engine oil or transmission fluid.


A/C REFRIGERANT SYSTEM COMPONENTS, REPLACING

^ If system is discharged as the result of a leaking component (except compressor),

- remove A/C compressor

- remove faulty component

- plug all open refrigerant line connections to prevent dirt and moisture contamination

- blow through component with compressed air and collect oil that runs out

- add same amount of new refrigerant (PAG) oil to new component plus amount listed below:

^ evaporator 20 cc (0.7 fl oz)
^ accumulator 30 cc (1.0 fl oz)
^ condenser 10 cc (0.3 fl oz)
^ refrigerant line/hose 10 cc (0.3 fl oz)

- install new component

- remove compressor oil drain plug, drain refrigerant oil from compressor and measure amount

Note
Rotate compressor by hand to speed up oil draining process. Dispose of used refrigerant oil following laws governing hazardous waste disposal.

CAUTION
In order to ensure lubrication during initial start-up, add a minimum of 80 cc (2.7oz) of fresh refrigerant (PAG) oil to A/C compressor.


- refill compressor with 80 cc (2.7 oz) of fresh refrigerant oil

- install oil drain plug

If total amount of refrigerant oil drained from old compressor was greater than 80 cc (2.7, oz),

- subtract 80 cc (2.7 oz) (amount of new oil that was added to compressor) from total amount

- add resulting amount of fresh refrigerant oil to either evaporator or accumulator

Example:
100 cc (amount of oil drained from old compressor)
-80 cc (amount of fresh oil added to new compressor)
------------------------------------------------------
20 cc (amount of fresh oil to be added to evaporator or accumulator)

Note
Some refrigerant/recovery/recycling/recharging equipment has provisions for adding refrigerant (PAG) oil during system recharge. If using this method for adding oil, follow all refrigerant/recovery/recycling/recharging equipment manufacturer's instructions.

- install A/C compressor

- evacuate and recharge A/C system

- manually rotate A/C compressor 10 rotations before operating system to prevent compressor damage

^ If system is leaking as the result of a damaged or faulty part (except compressor), but system is still charged,

- discharge A/C system

- remove faulty component and plug all open line connections

- blow through component with compressed air and collect oil that runs out

- add same amount of new refrigerant (PAG) oil to new component plus amount listed below:

^ evaporator 20 cc (0.7 fl oz)
^ accumulator 30 cc (1.0 fl oz)
^ condenser 10 cc (0.3 fl oz)
^ refrigerant line/hose 10 cc (0.3 fl oz)

- install new component

- evacuate and recharge A/C system


A/C COMPRESSOR, REPLACING

^ If A/C compressor is replaced new due to external compressor damage,

- discharge A/C system

- remove A/C compressor and plug all open line connections

- remove compressor oil drain plug, drain refrigerant oil from compressor and measure amount

Note
Rotate compressor by hand to speed up oil draining process. Dispose of used refrigerant oil following laws governing hazardous waste disposal.

- remove oil drain plug from new compressor

Note
Replacement A/C compressors supplied by the Parts Department are filled with 250cc +or- 20 cc (8.5 fl oz +or- 0.7fl oz) of refrigerant oil. This is the total system oil capacity

- drain fresh oil from new compressor and save (keep oil in an enclosed container to prevent moisture and dirt contamination)

CAUTION
in order to ensure lubrication during initial start-up, add a minimum of 80 cc (2.7 oz) of fresh refrigerant (PAG) oil to A/C compressor.


- refill new compressor with 80 cc (2.7 oz) of fresh refrigerant oil

- install oil drain plug

If total amount of refrigerant oil drained from old compressor was greater than 80 cc (2.7 oz),

- subtract 80 cc (2.7 oz) (amount of new oil that was added to compressor) from total amount

- add resulting amount of fresh refrigerant oil to either evaporator or accumulator

Example:

100 cc (amount of oil drained from old compressor)
-80 cc (amount of fresh oil added to new compressor)
--------------------------------------------------------------------
20 cc (amount of fresh oil to be added to evaporator or accumulator)


- install new A/C compressor

- evacuate and recharge A/C system

- manually rotate A/C compressor 10 rotations before operating system to prevent compressor damage

^ If A/C compressor is replaced new as the result of leakage or internal damage (for example noises or no output),

- discharge A/C refrigerant system

- remove A/C compressor

If A/C compressor has internal damage,

- check refrigerant lines and hoses for contamination (metal chips); if present, replace lines/hoses as necessary, accumulator and restrictor

Note
If lines/hoses are replaced, measure and add appropriate amount of PAG oil before installing. If accumulator is replaced, measure and add appropriate amount of PAG oil before installing.

- remove compressor oil drain plug, drain refrigerant oil from compressor and measure amount

Note
Rotate compressor by hand to speed up oil draining process. Dispose of used refrigerant oil following laws governing hazardous waste disposal.

- remove oil drain plug from new compressor

Note
Replacement A/C compressors supplied by the Parts Department are filled with 250 cc +/- 20 cc (8.5 fl oz +/- 0.7 fl oz) of refrigerant oil. This is the total system oil capacity

- drain fresh oil from new compressor and save (keep oil in an enclosed container to prevent moisture and dirt contamination)

CAUTION
In order to ensure lubrication during initial start-up, add a minimum of 80 cc (2.7oz) of fresh refrigerant (PAG) oil to A/C compressor.

- refill new compressor with 80 cc (2.7 oz) of fresh refrigerant oil

- install oil drain plug

If total amount of refrigerant oil drained from old compressor was greater than 80 cc (2.7 oz),

- subtract 80 cc (2.7 oz) (amount of new oil that was added to compressor) from total amount

- add resulting amount of fresh refrigerant oil to either evaporator or accumulator

Example:

100 cc (amount of oil drained from old compressor)
-80 cc (amount of fresh oil added to new compressor)
--------------------------------------------------------------------
20 cc (amount of fresh oil to be added to evaporator or accumulator)


Note
Some refrigerant/recovery/recycling/recharging equipment has provisions for adding refrigerant (PAG) oil during system recharge. If using this method for adding oil, follow all refrigerant/recovery/recycling/recharging equipment manufacturer's instructions.

- install new A/C compressor

- evacuate and recharge A/C system

- manually rotate A/C compressor 10 rotations before operating system to prevent compressor damage


ACCUMULATOR AND RESTRICTOR

Replace accumulator and restrictor whenever moisture or contamination (blockage) have entered refrigerant system.

- discharge A/C system

- remove A/C compressor and plug all refrigerant line connections

- remove compressor oil drain plug, drain old refrigerant oil from compressor and measure amount

Note
Rotate compressor by hand to speed up oil draining process. Dispose of used refrigerant oil following laws governing hazardous waste disposal.

CAUTION
In order to ensure lubrication during initial start-up, add a minimum of 80 cc (2.7oz) of fresh refrigerant (PAG) oil to A/C compressor.


- refill compressor with 80 cc (2.7 oz) of fresh refrigerant oil

- install oil drain plug

It total amount of refrigerant oil drained from old compressor was greater than 80 cc (2.7 oz),

- subtract 80 cc (2.7 oz) (amount of new oil that was added to compressor) from total amount

- add resulting amount of fresh refrigerant oil to evaporator

Example:

100 cc (amount of oil drained from old compressor)
-80 cc (amount of fresh oil added to new compressor)
-----------------------------------------------------
20 cc (amount of fresh oil to be added to evaporator)

Note
Some refrigerant/recovery/recycling/recharging equipment has provisions for adding refrigerant (PAG) oil during system recharge. If using this method for adding oil, follow all refrigerant/recovery/recycling/recharging equipment manufacturer's instructions.

- replace restrictor

- install A/C compressor

- remove accumulator and plug all open line connections

- blow through accumulator with compressed air and collect oil that runs out

- add same amount of new refrigerant (PAG) oil to new accumulator plus 30 cc (1.0 fl oz)

Note
Install new accumulator immediately after opening to prevent moisture contamination of desiccant.

- install new accumulator

- evacuate and recharge A/C system

- manually rotate A/C compressor 10 rotations before operating system to prevent compressor damage