E.Compressor (Off Car) -
FIGURE 5 - COMPRESSOR FLUSHING:
a. Mount the compressor in a vise over a drain pan using Compressor Holding Fixture J-9396 (A-6), J-33026 (DA-6), J-25008-A (R-4) or J-34992 (V-5).
b. Invert the compressor and drain the oil through the suction and discharge ports. Also drain A-6 and V-5 compressors through the crankcase oil drain plug. See "REFRIGERANT OIL DISTRIBUTION" procedures as outlined in the appropriate Service Information Manual.
c. Set the compressor in the upright position (suction/discharge ports pointing upwards) and force liquid R-11 into the compressor suction port (larger internal opening) until clean R-11 flows from the discharge port (smaller internal opening), see Figure 5. Use the large orifice nozzle flush gun J-33883-50 or equivalent.
d. Turn the compressor by rotating the clutch driver for 1 or 2 turns, if possible. DO NOT FORCE. R-11 will be pumped out of the discharge port (smaller internal opening).
e. Refill the compressor with R-11 (Figure 5) and cap the suction/ discharge ports with a compressor shipping cap. Rock or shake the compressor. Wait a minimum of 5 minutes before removing the cap, inverting the compressor (suction/discharge ports pointing towards the drain pan) and draining the compressor.
f. Force R-12 vapor into the compressor suction port (larger internal opening) to purge the remaining R-11, see Figure 5. Use the large orifice nozzle flush gun J-33883-50 or equivalent. Continue to blow R-12 vapor until no liquid is observed leaving the discharge port (smaller internal opening).
5. ADD 525 VISCOSITY REFRIGERANT OIL TO REFRIGERANT SYSTEM -
A. Drain as much oil as possible from the new or rebuilt compressor (see "DISCHARGING, ADDING OIL, EVACUATING AND CHARGING" procedures as outlined in the appropriate Service Information Manual). A residual quantity of refrigerant oil will remain in the the compressor that cannot be drained. A flushed compressor has no residual quantity of oil. The residual quantity of oil for a new or rebuilt compressor is as follows:
Total System Capacity Residual Quantity Add Quantity
A-6 -- 330 ml (11 fl.oz.) = 30 ml (1 fl.oz.) + 300 ml (10 fl.oz.)
DA-6 -- 240 ml (8 fl.oz.) = 45 ml (1.5 fl.oz.) + 195 ml (6.5 fl.oz.)
R-4 -- 180 ml (6 fl.oz.) = 30 ml (1 fl.oz.) + 150 ml (5 fl.oz.)
V-5 -- 240 ml (8 fl.oz.) = 45 ml (1.5 fl.oz.) + 195 ml (6.5 fl.oz.)
Total System Capacity is the proper refrigerant oil quantity for a new or totally flushed system. Add Quantity is the proper refrigerant oil quantity for a new or totally flushed system with a new or rebuilt drained compressor. If the accumulator, condenser, evaporator or any other air conditioning component is not flushed or replaced, the above table is not applicable. See "REFRIGERANT OIL DISTRIBUTION" procedures as outlined in the appropriate Service Information Manual to determine proper refrigerant oil quantity to be added.
B. Add the proper amount of new 525 viscosity refrigerant oil back into the compressor so that the total system capacity is correct. This will ensure the refrigerant system has the proper oil charge.
It is extremely important that the refrigerant system has the proper oil charge. Failure to maintain the proper oil charge may result in compressor damage and poor performance.
6. REASSEMBLE AIR CONDITIONING REFRIGERANT SYSTEM -
A. Install the air conditioning compressor on the vehicle.
B. Install the accumulator. The accumulator should remain capped until just prior to making final air conditioning system connections.
C. Replace the O-ring on the expansion (orifice) tube, if the expansion tube is reused. Lubricate the O-ring with 525 viscosity refrigerant oil. Insert the expansion tube into the liquid line (smaller screen end first) and push until the expansion tube reaches a firm stop. This indicates proper seating of the O-ring.
O-Ring (Standard and Captured):
O-Ring Location:
D. Install new G.M. approved service replacement air conditioning O-rings at all disassembled fittings, except where provided on new componenets. The connection fitting design should be carefully identified to ensure installation of the correct air conditioning service replacement O-ring, see Figure 6. Some connections will implement a "captured" O-ring design fitting that uses a groove to retain the O-ring, while others do not have a groove and use a "non-captured" or "standard" O-ring. Before installation, verify that both O-rings and fittings have not been nicked or deformed. Always slip the O-ring onto the flange tube to ensure proper locating and sealing. Failure to use the proper service replacement parts and procedures may result in excessive Refrigerant 12 leakage.
E. Connect all refrigerant lines and hoses. Tighten the connections following the "HANDLING OF REFRIGERANT LINES AND FITTINGS" procedure as outlined in the appropriate Service Information Manual.
7. EVACUATE AND CHARGE REFRIGERANT SYSTEM -
A. Evacuate the air conditioning system until a vacuum of 95-98 kPa (28-29 In. Hg.) or altitude adjusted is attained and can be held for 5 minutes, without the vacuum pump operating. See "DISCHARGING, ADDING OIL, EVACUATING AND CHARGING" procedures as outlined in the appropriate Service Information Manual. When evacuating, the inability to initially draw a vacuum does not necessarily indicate a system leak since proper evacuation vacuum levels will not be obtained until all of the liquid R-11 boils off and is evacuated. It is normal for the evacuation vacuum level to remain low (5-20 In. Hg.) for a period of time (5 minutes or longer depending if liquid R-11 was left in the system).
It is extremely important that the refrigerant system is properly evacuated.
Failure to evacuate the refrigerant system may result in compressor damage
and poor performance.
B. Insert a 0.48 kg. (1 lb.) charge of R-12 and leak check, if no leak is present, charge the air conditioning system with the recommended amount of R-12. See "AIR CONDITIONING SYSTEM REFRIGERANT CAPACITY" in the appropriate Service Manual.
Tools Required:
1. Flush Gun Kit - (J-33883-A)
2. Air Conditioning Hose End Caps and Plugs
3. Assorted Fill and Drain Tubes
4. Compressor Holding Fixture J-9396 (A-6), J-33026 (DA-6), J-25008-A (R-4) or J-34992 (V-5).
Use of the R-11 in accordance with these instructions permit effective performance of the product without damaging the air conditioning system.
For warranty purposes when performing Air Conditioning System Flushing on a Cadillac, use Operation No. D4440 (Compressor Assembly - Replace) and add 1.8 hours to regular labor hours for component removal (accumulator, hoses and lines), flushing and installation (does not include system recharge).