Technical Instructions
A) Functional Check^ Start car and activate air conditioning system.
1) If air conditioner operates satisfactorily, proceed to step B.
2) If air conditioning system is inoperative (compressor does not work) proceed to step C.
B) Replacement of Fuel Cooler (928 573 063 02)
^ Completely discharge air conditioning system.
Caution:
Adhere to safety rules in handling Freon.
^ Disconnect battery.
^ Remove complete air filter (lower part is to be flipped over thus oil breather hose does not need to be disconnected)
Replace fuel cooler in the following sequence:
^ Disconnect right A/C Freon pipe.
^ Disconnect fuel lines.
^ Remove fuel cooler bracket.
^ Disconnect left A/C Freon pipe.
Install new fuel cooler in reverse sequence.
Note:
Do not twist fuel cooler. Fuel line connections must point downward.
^ Reconnect battery.
^ Start engine for approximately 15 seconds.
^ Recheck fuel line connections for leaks.
^ Reinstall air filter housing.
Note:
For easy installation coat flange of air distributor slightly with oil.
^ Flush A/C system using 300g (1.6 fluid oz) of Freon filled into the high pressure line.
^ Perform Freon leak test at fuel cooler.
^ Discharge system again at low pressure line and evacuate system for approximately one (1) hour.
^ Refill A/C system with 1030g (36 fluid oz.) of Freon.
C) Replacement of fuel cooler and a/c receiver dryer and compressor (928 573 063 02 and 000 043 029 00).
^ Drive vehicle onto lift.
^ Completely discharge A/C system.
Caution:
Adhere to safety rules in handling Freon.
^ Remove complete air filter (lower part to be flipped over, thus oil breather hose does not need to be disconnected).
^ Disconnect battery.
Replace fuel cooler in the following sequence:
^ Disconnect right A/C Freon pipe.
^ Disconnect fuel lines.
^ Remove fuel cooler bracket.
^ Disconnect left A/C Freon pipe.
^ Lift vehicle.
^ Remove A/C compressor.
Note:
Remove A/C bracket then lift air pump bracket to get to second A/C compressor bolt.
^ Remove A/C receiver dryer.
^ Remove temperature switch from receiver dryer and install into new dryer - use new seal from kit.
^ Use compressed air to clean-out Freon lines including condenser (blow through from receiver dryer side). Prior to installation of new compressor:
^ Carefully remove plastic caps and let Freon escape. Remove 80 cc (2.7 fluid oz.) oil from compressor since this amount is already in the system.
^ Install compressor, connect lines by using new seals part numbers 928 573 637 02 and 928 573 635 02, slightly coating seals with refrigeration oil.
^ Properly route Freon lines.
^ Tension A/C belt.
^ Install new fuel cooler in reverse sequence of removal.
Note:
Do not twist fuel cooler. Fuel line connections must point downward.
^ Install new receiver dryer, use new seals from kit.
^ Flush A/C system by using 300g (10.6 fluid oz.) of Freon filled into the high pressure line.
^ Check for leaks (Freon leak test) on all connections.
^ Discharge system again at lower pressure line.
^ Connect battery.
^ Start engine for approximately 15 seconds.
^ Recheck fuel line connections for leaks.
^ Flush system second time with 300g (10.6 fluid oz.) of Freon.
^ Discharge system again - evacuate system for approximately one (1) hour.
^ Refill system with 1O3Og (36 fluid oz.) of Freon.
^ Check operational function of A/C system.