A/C Component Replacement Requirements
Set, A/C Fittings:
SPECIAL TOOL(S)
CAUTION: Follow all refrigerant system safety precautions.
1. An A/C kit has been released to provide the necessary equipment and information to perform the new, mandatory A/C system filtering procedure.
2. Perform the Refrigerant Discharging and Recovery Procedure. For additional information, refer to Refrigerant Discharging and Recovery Procedure. Refrigerant Discharging and Recovery procedure
3. To determine that the A/C compressor has failed and must be replaced, remove the A/C evaporator core orifice and condenser to evaporator tube, if necessary. Look for a dirty A/C evaporator core orifice or a condenser to evaporator tube containing black refrigerant oil and particles.
4. Remove the damaged A/C compressor.
NOTE: Cap all open refrigerant lines and components to prevent entry of dirt and moisture.
5. Add new refrigerant oil to the new A/C compressor. For additional information, refer to Refrigerant Oil Addition. Refrigerant Oil Addition
NOTE:
- New FS-10 compressors do not contain any refrigerant oil.
- The correct amount of refrigerant oil must be added to the new A/C compressor before installation. For additional information, refer to Refrigerant Oil Addition. Refrigerant Oil Addition
6. Install the new A/C compressor.
NOTE: The A/C clutch may have to be transferred to the new A/C compressor.
7. Remove the suction accumulator.
8. Add clean refrigerant oil to the new suction accumulator. For additional information, refer to Refrigerant Oil Addition. Refrigerant Oil Addition
9. Install the suction accumulator.
10. Get the correct repair kit for the vehicle on which you are working. Filter kit with the SPN suffix A is used on vehicles with a nylon lined evaporator to compressor suction line.
Filter For Nylon Hose:
11. Remove a length of evaporator to compressor suction line to accommodate the suction filter and install the filter using the clamps provided with the kit. Be sure the filter is correctly oriented for refrigerator system flow. Check the label on the filter. On the filter for the nylon lined evaporator to compressor suction line, install O-rings (two on each filter tube being sure they are properly seated in the grooves on the tube). Tighten the clamps securely.
12. Install a new A/C evaporator core orifice.
13. Install a pancake filter in the condenser to evaporator tube between the A/C condenser core and the A/C evaporator core orifice. Be sure the filter inlet is toward the A/C condenser core. Connections can be made using A/C Test Fitting Set and flexible refrigerant hose of 172 bar (17200 kPa, 2500 psi) burst rating. Individual fittings are also available.
14. Evacuate, charge and leak test the system. For additional information, refer to Evacuation and Charging. Evacuation and Charging Procedure
15. Check all refrigerant system hoses, lines and the positioning of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments.
16. Provide adequate air flow to the front of the vehicle (with a fan, if necessary), and set the selector valve at MAX A/C. Set the blower motor on HIGH and temperature control at full cool. Start the engine and let it idle briefly. Make sure the A/C system is operating correctly.
17. Gradually bring the engine up to 1200 RPM by running it at lower RPMs for short periods (first at 800 RPM, then at 1000 RPM). Set the engine at 1200 RPM and run it for an hour with the A/C system operating.
18. Stop the engine.
19. Perform the Refrigerant Discharging and Recovery Procedure. For additional information, refer to Refrigerant Discharging and Recovery Procedure. Refrigerant Discharging and Recovery procedure
20. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the condenser to evaporator tube.
21. Discard the pancake filter. It can be used one time only.
22. Reconnect the condenser to evaporator tube back into the system
23. Evacuate, charge and leak test the system. For additional information, refer to Evacuation and Charging. Evacuation and Charging Procedure
24. Check the operation of the A/C system in all modes.