A/c System General Servicing Chevrolet Camaro II

SYSTEM SERVICING CAUTIONS

BEFORE OPENING THE SYSTEM

Before disconnecting any lines or fittings, the system must be completely discharged using approved refrigerant recovery/recycling equipment.

DISCONNECTING LINES & FITTINGS

1. After system is discharged, carefully clean entire area around coupling nut to prevent dirt from entering system. Always use 2 wrenches to avoid twisting or distorting lines and fittings (hold fitting with one wrench while loosening coupling nut with second wrench).
2. Ford spring-coupling fittings require a special coupling tool (Motorcraft YT 1056) to open or close. See procedure under Connecting Lines and Fittings.
3. Cap or plug all LINES and FITTINGS immediately to prevent entry of air and moisture into system. Do not remove these caps until connections are being made.

COMPONENT REPLACEMENT

When components are replaced, system oil level must be adjusted. Add refrigeration oil to replacement component. See Compressor Oil Checking in this article, as well as, Component Oil Replacement Quantities chart under A/C SYSTEM SERVICE SPECIFICATIONS - CAR or TRUCK in this article.

CONNECTING LINES & FITTINGS

1. A new "O" ring should be used in all instances when connecting lines and fittings (dip "O" ring in clean refrigeration oil and make certain it is not twisted during installation). Always use 2 wrenches to avoid twisting or distorting lines and fittings. Tighten coupling nuts securely.
2. Ford spring-coupling fittings require a special coupling tool (Motorcraft YT 1056) to open or close. Use the following procedure to connect or disconnect the spring-coupling fitting.

PLACING SYSTEM IN OPERATION

After component replacement and/or system servicing has been completed and all connections have been made, proceed as follows

1. Evacuate the system using vacuum pump.
2. Charge the system with R-12. See REFRIGERANT CAPACITIES in A/C SYSTEM SERVICE SPECIFICATIONS - CAR or TRUCK in this article.
3. Leak-test the system, with particular attention to all new connections and components.
4. Make a performance test of the system. Never assume that a Recharging has automatically corrected a problem.

COMPRESSOR OIL CHECKING

Some models have compressor-mounted service valves that allow oil checking by isolating the compressor. On all others, system must be discharged using approved refrigerant recovery/recycling equipment and compressor may need to be removed to check oil. After oil level is checked and adjusted, A/C system must be evacuated and recharged.

ISOLATING COMPRESSOR

1. Connect manifold gauge set to service valves on compressor. Close both gauge valves. Open both service valves to the mid-position.
2. Start engine and operate air conditioning. Turn suction service valve slowly clockwise toward front-seated position. When suction pressure is reduced to zero or less, stop engine and quickly close suction service valve (front-seated).
3. Front-seat the discharge valve. Loosen oil check plug slowly to release any internal pressure. Service valves can now be removed from compressor and compressor removed from vehicle (if necessary). Purge compressor after servicing.

PURGING COMPRESSOR

1. Remove gauge set and place caps on service valve ports. Back-seat the suction service valve to allow refrigerant to enter compressor.
2. Loosen discharge port valve slightly. Loosen valve port cap to allow refrigerant to force out air from compressor. Back-seat the discharge valve and tighten the port cap. Compressor is ready for service.

REFRIGERATION OIL

Only new, pure, moisture-free refrigeration oil should be used in the air conditioning system. This oil is highly refined and dehydrated (moisture content less than 10 parts per million). Refrigeration oil container must be kept tightly closed at all times when not in use, or moisture will be absorbed from the air and introduced into the refrigeration system.

GENERAL INFORMATION

Note. Harrison Compressors, built by the Harrison Radiator Division of General Motors, may have been referred to in the past as Frigidaire, General Motors or Delco-Air Compressors.

The system is fully charged with 10 ounces of refrigeration oil. It will not normally require addition of oil unless definite oil loss has occurred due to ruptured line, leaking compressor seal, replacement of system component, compressor overhaul, or vehicle collision.

NO SIGN OF OIL LEAKAGE

1. Remove compressor. Drain and measure oil. When replacing compressor, replace the amount drained plus one ounce. If the amount drained from compressor is over 8 ounces, system must be flushed. Replace accumulator and install compressor filled with 10 ounces total.
2. If evaporator is replaced, add 3 ounces to the new evaporator. If condenser is replaced, add one ounce. If accumulator is replaced, drain old accumulator and measure oil. Add the same amount, plus 2 ounces, to the new accumulator.

SIGNS OF EXCESSIVE OIL LEAKAGE

1. Remove compressor and accumulator. Drain and measure total oil from both components. If less than 6 ounces, add 6 ounces to the system. If more than 6 but less than 8 ounces, add the amount drained. If a new accumulator is installed, add 2 additional ounces to compensate for oil retained in the desiccant.
2. If amount drained is more than 8 ounces, flush system. Replace accumulator. Install compressor filled with 10 ounces total.

Note. If oil drained contains metal chips or other foreign material, flush system. Replace expansion tube, accumulator, and other components as necessary.

Note. Harrison Compressors, built by the Harrison Radiator Division of General Motors, may have been referred to in the past as Frigidaire, General Motors or Delco-Air Compressors.

1. When a DA V5 compressor is removed from the vehicle for servicing, the amount of oil remaining in the compressor should be drained and measured. This oil should then be discarded and new refrigerant oil added. NOTE: Drain oil from the oil drain plug open to insure complete draining of oil from the compressor
2. The compressor has a unique lubrication system. The crankcase-suction bleed is routed through the rotating swashplate for lubrication of the swashplate bearing. The rotation acts as an oil separator, which removes some of the oil from the crankcase-suction bleed, re-routing it to the crankcase where it can lubricate the compressor mechanism.
3. Up to 4 ounces of oil can collect in the crankcase. All replacement compressors will be shipped from the factory with 8 ounces of oil in the crankcase. The oil must be drained from the oil drain plug opening and retained. Replace the oil in the same quantity as previously drained from the old compressor.

Note. If a new accumulator must be added to the DA V5 system, add an additional 2 ounces of oil to the compressor to compensate for that retained by the original accumulator desiccant.

Note. Harrison Compressors, built by the Harrison Radiator Division of General Motors, may have been referred to in the past as Frigidaire, General Motors or Delco-Air Compressors.

Systems with this compressor are fully charged with 8 ounces of refrigeration oil. Due to the compressor's design (without oil sump), the compressor does not have to be removed for oil measurement. Note the following situations for checking and adding oil with this system

NO SIGN OF EXCESSIVE OIL LEAK

1. If compressor is replaced, remove, drain and measure oil. Replace with same amount of new oil plus one ounce. If evaporator is replaced, add 3 ounces of new oil. If condenser is replaced, add one ounce.
2. If accumulator is to be replaced, remove, drain oil, and measure. Replace with same amount of new oil, plus 3 ounces. If no oil can be drained from old accumulator, add 2 ounces of new oil.

1. As the DA-6 compressor has no oil sump, the compressor retains a minimum of refrigeration oil. Therefore, only the accumulator needs to be removed, drained, and its oil measured.
2. If the amount recovered is less than 3 ounces, add 3 ounces of new oil to the system. If the amount is more than 3 ounces, add the same amount of new oil as that drained from the accumulator.

Note. If a new accumulator must be added to the DA-6 system, add an additional 3 ounces to compensate for that retained by the original accumulator desiccant.

Note. Harrison Compressors, built by the Harrison Radiator Division of General Motors, may have been referred to in the past as Frigidaire, General Motors or Delco-Air Compressors.

Systems with this compressor are charged (new) with 6 ounces of refrigeration oil. Due to compressor's design (without oil sump), compressor does not have to be removed for oil measurement. Note the following situations for checking and adding oil with this compressor

1. If compressor is replaced, remove, drain and measure oil. Replace with same amount of new oil plus one ounce. If evaporator is replaced, add 3 ounces of new oil. If condenser is replaced, add one ounce. NOTE: Also see Component Oil Replacement Quantities chart under A/C SYSTEM SERVICE SPECIFICATIONS - CAR or TRUCK in this article.
2. If accumulator is to be replaced, remove, drain oil, and measure. Replace with same amount of new oil, plus 2 ounces to compensate for that retained by the original accumulator's desiccant.

SIGNS OF EXCESSIVE OIL LOSS

If system has lost excessive oil, remove the accumulator, drain and measure oil. DO NOT remove or drain compressor. If more than 3 ounces is found in accumulator, add same amount of new oil as was drained. If less than 3 ounces is measured, add 3 ounces of new oil. If a new accumulator is being installed, add 2 additional ounces of oil to replacement accumulator.

OIL CHARGE DOUBTFUL OR SYSTEM CONTAMINATED

If exact quantity of oil in system is in doubt or oil drained from components contains foreign particles, drain and flush system. Then, add a new charge of 6 ounces of refrigeration oil to system.

Scheme 109

1. After the compressor and system have been run, stop the engine. Slowly discharge system using approved refrigerant recovery/recycling equipment. Clean and cool dipstick with R-12. (Scheme 109): Sanden (Sankyo) 5-Cylinder Compressor Oil Check
2. Loosen the compressor mounting bolts, remove the drive belt, and move the compressor to a bench for easiest and most accurate measurement. Position the compressor so that the oil fill plug is at top dead center.
3. Thoroughly clean the oil fill plug and the area around it. Loosen the fill plug slowly to allow trapped refrigerant pressure to escape through the loosened threads.
4. The front plate hub has a lobe, which is indexed (notched) 180° from TDC of the cam rotor. Rotate the hub plate lobe until the index notch is 110° from bottom center. (Scheme 109) Check this position by looking through the oil fill hole and noting that the ball end of the top piston rod lines up with the fill hole.
5. Looking at the front end of the compressor, insert the dipstick diagonally from upper left to lower left until the dipstick stop contacts the filler hole surface. Remove dipstick and note oil level. Oil level should be between the 4th and 6th increment on the dipstick (3-4 ounces). Add oil as necessary.
6. If system components are being replaced, add refrigerant oil directly to them as indicated in the chart under Component Oil Replacement Quantities chart under A/C SYSTEM SERVICE SPECIFICATIONS - CAR or TRUCK in this article.

REMOVAL & INSTALLATION

1. Discharge refrigerant from system using approved refrigerant recovery/recycling equipment and disconnect liquid line at evaporator inlet. Remove orifice tube using needle nose pliers or orifice tube remover tool (Kent-Moore tool J 26549C or equivalent).
2. If difficulty in encountered during removal of a plugged or restricted orifice tube, remove as much impacted residue as possible. Using a heat gun, hair drier, epoxy drier or equivalent, carefully apply heat 1/4" from dimples on inlet pipe. Be careful not to overheat pipe. NOTE: If system has a pressure switch near orifice tube location, remove the switch prior to heating inlet pipe to avoid damage switch.
3. While heat is being applied, install orifice tube extractor tool (Kent-Moore tool J 26549 10 or equivalent) or remover tool (Kent-Moore tool J 26549C or equivalent). Use a turning motion along with a push-pull motion to loosen orifice tube and remove it.
4. To install orifice tube, swab inside of inlet pipe with R-11 or equivalent solvent. Add 1 oz. of refrigerant oil to system. Lubricate new orifice tube and "O" ring with refrigerant oil and insert into the inlet pipe. Install orifice tube with shorter screen end first.
5. Reverse the rest of removal procedure to complete installation. Recharge system and test system for proper operation.

DIAGNOSTIC PROCEDURES

Diagnosis is an important first step in A/C system servicing. To save time and effort, systems should be carefully checked to identify the causes of poor performance. By using the following diagnostic charts, defective components or system damage can be quickly located. To identify problems that are specific to one system, refer to the appropriate MANUAL A/C-HEATER SYSTEM, AUTO A/C-HEATER SYSTEM, or COMPRESSOR OVERHAUL repair article in this section. The charts in this article apply to all systems.

PREPARATION FOR TESTING

1. Attach Low and High side gauges.
2. Start engine and allow it to warm up.
3. Set system to COOL and blower to HIGH.
4. Open car doors and hood.
5. Run at fast idle for 2-3 minutes.

ALTITUDE PRESSURE VARIATIONS

ALTITUDE PRESSURE VARIATIONS

ALTITUDE VACUUM VARIATIONS

OPERATIONAL TEST GAUGE READINGS

NORMAL SYSTEM OPERATING PRESSURES (PSI) (1)

Air Conditioning System Performance Check. Scheme 110

Ambient Temperature/Pressure Chart. Scheme 111

Evaporator Temperature/Pressure Chart. Scheme 112

A/C SYSTEM DIAGNOSIS WITH GAUGES

DIAGNOSIS WITH GAUGES - SYSTEMS WITH INSUFFICIENT OR NO COOLING

A/C SYSTEM SERVICE SPECIFICATIONS - CAR MODELS

SYSTEM REFRIGERANT CAPACITIES

COMPONENT OIL REPLACEMENT QUANTITIES

COMPRESSOR BELT TENSION (Lbs.) (1)

COOLING SYSTEM CAPACITIES (BUICK)

COOLING SYSTEM CAPACITIES (CADILLAC)

COOLING SYSTEM CAPACITIES (CHEVROLET)

COOLING SYSTEM CAPACITIES (OLDSMOBILE)

COOLING SYSTEM CAPACITIES (PONTIAC)

A/C SYSTEM SERVICE SPECIFICATIONS - TRUCK MODELS

A/C SYSTEM REFRIGERANT CAPACITIES - TRUCKS

COMPRESSOR BELT TENSION (Lbs.) - TRUCK MODELS (1)

COMPONENT OIL REPLACEMENT QUANTITIES - TRUCK

COOLING SYSTEM CAPACITIES - TRUCKS