Instructions For '90-93 Legacy Zexel Systems

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. Use touch-up paint to paint the sight glass on replacement receiver/drier; part # 73031AA210. The sight glass cannot be utilized in testing R-134a performance.

6. Remove and discard the receiver/drier O-rings and replace with new O-rings, part number: 73039AA200.

7. Install the replacement receiver/drier, part number: 73031AA210, to the vehicle and connect the pressure switch electrical connection.

8. Remove and discard the suction refrigerant hose, retain all hardware, and add 200cc PAG retrofit 100 oil, part number: 73019AA110, to the compressor.

9. Install new suction hose, part number: 73054AA620 (73054AA400 for '93 Model), using all applicable O.E. hardware. Lubricate the suction hose O-rings before installation.

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

11. Install new discharge hose, part # 73054AA600 (73054AA630 for '92 Model); (73054AA640 for '93 Model) using all applicable O.E. hardware. Lubricate the discharge hose O-rings before installation.

12. Evacuate the A/C system for 30 minutes using R-134a equipment.

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

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

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

13. Charge system with 1.87 lb./30 oz/850 gm R-134a refrigerant and operate the system for 10 minutes at idle. Install the R-134a service caps (the caps are an important part of the service valve seal), and perform a leak test.

14. 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.

15. Fill out the R-134a retrofit label, part number: SOA523Z500, by lifting white backing tape and writing in oil type PAGR 100, the oil amount 200cc, and the R-134a charge amount 1.87 lb./30 oz/850 gm. Locate the label in a highly visible location such as the fire wall or hood. Pull the backing off the label and cover the label with the clear portion of the label.

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