Instructions For '90-91 Legacy Calsonic Systems (Inc. Turbo)

NOTES:

1. Always lubricate all O-rings with PAG oil before installation.
2. Always tighten fittings to proper torque specifications.
3. Observe all safety recommendations.
4. System to be serviced by qualified personnel.

1. Repair any problems or leaks before beginning retrofit procedure.

2. Disconnect negative battery cable.

3. Recover all R-12 refrigerant from the vehicles A/C system utilizing a UL approved R-12 recovery device.

4. Disconnect the electrical connection from receiver/drier pressure switch and remove the existing R12 receiver/drier from the vehicle and discard. Allow as much oil as possible to drain from A/C hoses or pipes.

5. On the attachment block surface that contacts the receiver/drier, remove the GUIDE PIN and make sure that the block surface is flat after removal.

6. Use touch-up paint to paint the sight glass on replacement receiver/drier; part # 73411FA100. The sight glass can not be utilized in testing R-134a performance.

7. Remove and discard the receiver/drier O-rings and replace with new O-rings, part number: 73039AAO10. Lubricate O-rings with the specified PAG oil lubricant.

8. Install the replacement receiver/drier, P/N: 73411FA100, to the vehicle, torque to the proper specification, and connect the pressure switch electrical connection.

9. Remove the compressor from the vehicle.

CAUTION:
hoses or block fittings on hose assemblies should be capped or protected from foreign matter entering the system.

10. Remove and discard the compressor pressure relief valve and then drain as much mineral oil as possible from the compressor body. Drain mineral oil from the cylinder head, suction and discharge ports while turning the shaft with a socket wrench on the clutch armature nut.

11. Install the replacement compressor relief valve, part number: 73035AA10O. Lubricate O-rings with the specified PAG oil lubricant and reinstall the compressor.

12. Remove and discard the suction refrigerant hose, retain all hardware, and add 236cc of PAG oil lubricant, P/N: 73019AA100, to the compressor.

13. Install new suction hose, part number: 73054AA141 (73054AA311 for Turbo), using all applicable O.E. hardware. Lubricate the suction hose O-rings before installation.

14. Install an adapter valve - suction hose, P/N: 73058AA100 to the low pressure suction hose. Torque the adapter to proper specification.

15. Remove the discharge refrigerant hose and retain all hardware.

16. Install new discharge hose, part number: 73054AA081, using all applicable O.E. hardware. Lubricate the discharge hose O-rings before installation.

17. Install an adapter valve - discharge hose, P/N: 73058AA110 to the high pressure discharge hose. Torque the adapter to proper specification.

18. Vacuum the A/C system for a minimum of 30 minutes.

^ After 10 minutes close the manifold gauge valves & perform a "VACUUM LEAK TEST".

^ After 5 minutes re-check the low pressure gauge reading. If the vacuum level has changed more than 1 in HG, perform an electronic leak test of the system.

^ If no leak is indicated resume evacuation (remaining 20 minutes).

19. Charge system with 23 oz./0.65 kg. R-134a refrigerant and operate the system for 10 minutes at idle. Install the R-134a service caps (the cap is an important part of the service valve seal), and perform leak test.

20. Remove and discard the existing refrigerant R-12 system label from upper radiator core support. Paint upper radiator core support if damaged during removal of label.

^ Fill out the retrofit label by lifting white backing tape and writing in oil type

^ PAGR 100, the oil amount 236cc, and the R134a charge amount 23 oz./ 0.65 kg. Locate the label in a highly visible location such as the fire wall or hood. Pull white backing off the label and cover the label with the clear portion of label.

^ Conduct a performance test. Reference service manual for R-134a performance characteristics.