Replacing Components
- The following replacement parts (compressor, accumulator, evaporator and compressor) are shipped charged with nitrogen gas. With time this charge drops, i.e. the pressure of the nitrogen charge is so small, that upon first opening gas may not escape.
- All components of the refrigerant system which are being sent in for quality monitoring, should be closed (use original threaded assembly of replacement parts).
NOTE: Since in the replacement part process parts can be stored for a longer period of time and at various locations, it could happen that when first opened (even with parts of the same number) gas may or may not escape. Therefore, remove sealing caps carefully on connectors of parts and allow nitrogen gas to release slowly
- Close all open connectors and lines to prevent moisture penetration.
- Replace restrictor.
CAUTION! Dispose of used refrigerant oil following local laws governing hazardous waste disposal Do not combine PAG oil with engine oil or transmission fluid.
For leaking or damaged components (except for compressor and accumulator), A/C system was completely empty (no charge):
- Remove malfunctioning component.
- Remove compressor.
- Remove oil drain plug from compressor.
NOTES:
- Rotate compressor manually to speed up oil draining process.
- The compressor oil drain plug O-ring has been replaced with a sealing ring (always replace).
- Drain old refrigerant oil out of compressor into a measuring container. Record volume of refrigerant oil drained.
- Subsequently, fill compressor with new refrigerant oil equal to the amount of oil drained in previous step.
NOTES:
- Fill amounts for refrigerant oil Refrigerant Oil
- To ensure adequate compressor lubrication, add at least 80 cubic cm (2.7 oz) of refrigerant oil into compressor, the remainder can be added to new accumulator.
- If there is dirt in the compressor of an open A/C system (e.g. during an accident), replace compressor.
- Blow through circuit with compressed air and nitrogen. Flushing With Compressed Air and Nitrogen
- Replace accumulator and restrictor.
- Assemble A/C system, evacuate and charge
For leaky or damaged components (except for the compressor and accumulator) there is still refrigerant in the A/C system:
- Discharge A/C system.
- Remove malfunctioning component, blow through with compressed air, collect all exhausted oil in a measuring container.
Refrigerant oil amount blown out of system, plus 20 cubic cm (0.7 oz) in evaporator, plus 10 cubic cm (0.3 oz) from condenser, refrigerant lines and hoses, is replaced as new refrigerant oil amount in the new component.
- Replace restrictor.
- Assemble A/C system, evacuate and recharge.
Replace compressor, without it being necessary to blow through the refrigerant system with compressed air and nitrogen (e.g. exterior damage after an accident):
- Discharge A/C system.
- Remove damaged compressor.
- Remove oil drain plug from compressor.
- Drain old refrigerant oil out of malfunctioning compressor into a measuring container. Record volume of drained refrigerant oil.
NOTES:
- Rotate compressor manually to speed up oil draining process.
- The compressor oil drain plug O-ring has been replaced with a sealing ring (always replace).
- Drain refrigerant oil also out of replacement compressor into a clean container. Refill replacement compressor with amount of fresh oil equal to the amount poured out of malfunctioning compressor.
Example: From the malfunctioning compressor only 70 cubic cm (2.4 oz) of refrigerant oil was poured out. From the replacement compressor 220 cubic cm of refrigerant oil poured out (a small amount remains in compressor). 70 cubic cm (2.4 oz) of refrigerant oil needs to be poured back into replacement compressor (oil originally from replacement compressor, held in clean container).
NOTE: If a larger amount of refrigerant oil poured out of the malfunctioning compressor more than approx. 80 cubic cm (2.7 oz) the remaining refrigerant oil can be used for the condenser or accumulator
- Replace restrictor.
- Assemble A/C system, evacuate and recharge.
Replace compressor due to leaks or interior damage (e.g. noises or no power):
- Discharge A/C system.
- Remove compressor.
NOTES:
- If there is interior damage (to compressor), check refrigerant hoses.
- If there are chips embedded, replace hose.
- Blow through A/C system with compressed air and nitrogen. Flushing With Compressed Air and Nitrogen
- Replace accumulator and restrictor.
- Assemble A/C system, evacuate and charge.
Replace accumulator and restrictor after blowing through the A/C system e.g. caused by penetrating moisture (the A/C system was open over a long period of time) or contamination (dirt):
- Discharge A/C system.
- Remove compressor.
- Eliminate cause of malfunction.
- Blow through A/C system with compressed air and nitrogen. Flushing With Compressed Air and Nitrogen
- Remove oil drain plug out of compressor.
- Drain old refrigerant oil out of compressor into measuring container.
- Record volume of refrigerant oil drained.
NOTES:
- Rotate compressor manually to speed up oil draining process.
- The compressor oil drain plug O-ring has been replaced with a sealing ring (always replace).
- Fill compressor with new refrigerant oil: the amount of oil must be equal to amount of old refrigerant oil drained.
NOTES:
- Fill amounts for refrigerant oil Refrigerant Oil
- To ensure adequate compressor lubrication, add at least 80 cubic cm (2.7 oz) of refrigerant oil into compressor. The remainder can be added to new accumulator.
- If there is dirt in the compressor of an open A/C system (e.g. during an accident), replace compressor.
- Blow through A/C circuit with compressed air and nitrogen.
- Replace accumulator and restrictor.
- Assemble A/C system, evacuate and charge.
Replace accumulator, without it being necessary to blow through A/C system with compressed air and nitrogen (e.g. damage caused by an accident), no refrigerant flowed out and no moisture and dirt have penetrated the circuit:
- Discharge A/C system.
- Replace restrictor.
- Remove accumulator.
- Clean accumulator.
- Weigh removed accumulator.
- Fill new accumulator with new refrigerant oil until it weighs as much as removed accumulator.
- Install accumulator.
- Assemble A/C system, evacuate and recharge.