ISOLATING COMPRESSOR
Note. Only compressors with stem-type service valves can be isolated.
- Connect service gauge set to the compressor service valves and open compressor valves slightly (turn in clockwise). Start engine and operate air conditioning. Slowly turn compressor suction valve clockwise toward closed (front-seated) position.
- When suction pressure is reduced to zero or less, turn off engine and compressor and quickly turn suction valve stem in to full front-seated position. Suction pressure should be slightly above zero. Turn discharge valve into front-seated position.
- To check oil level, slowly open compressor crankcase plug to relieve any remaining pressure. After oil level is corrected, cap service gauge ports on both valves. Back-seat suction service valve to allow refrigerant to enter compressor. Open discharge valve halfway.
- Loosen discharge service valve cap, allowing refrigerant pressure to force air out of compressor. Back-seat service valve and tighten cap. Compressor is now ready for operation.
REFRIGERANT OIL
Only new, pure, moisture-free refrigerant oil should be used in the air conditioning system. This oil is highly refined and dehydrated to a point where moisture content is less than 10 parts per million. The oil container must be tightly closed at all times when not in use, or moisture will be absorbed into the refrigerant oil from the air.
SERVICING PRECAUTIONS
Note. Recent findings by the EPA indicate that refrigerant is harmful to the earth's protective Ozone layer. When discharging refrigerant, DO NOT allow refrigerant to enter the atmosphere. If available, use refrigerant recovery/recycle systems when discharging system. Always follow manufacturer's instructions.
DISCHARGING SYSTEM PRECAUTIONS
If compressor has stem-type service valves, it can be isolated and removed without discharging entire system. See ISOLATING COMPRESSOR at the beginning of this article. Otherwise, discharge system completely before loosening any fittings.
CONNECTING LINES AND FITTINGS
A new gasket or "O" ring should be used in all instances when connecting lines or fittings. Dip "O" ring in new refrigerant oil and ensure it is not twisted during installation. Always use 2 wrenches to prevent damage to lines and fittings.
CALSONIC V5 5-CYLINDER
- Before checking and adjusting oil level, operate compressor at 1000-1500 engine RPM, and set controls at maximum cooling and blowing speed for 20-30 minutes to return oil to compressor.
- Stop engine. Discharge refrigerant and remove compressor from vehicle. See SERVICING PRECAUTIONS at the beginning of this article. Drain compressor oil from compressor discharge port and measure oil amount. Oil may be hard to drain if compressor is cool. Drain oil while compressor is warm.
- If amount drained is less than 3.2 ounces, conduct leak tests at system connections. Repair or replace faulty parts as necessary. Check purity of oil and oil level as follows.
- If amount drained is more than 3.2 ounces, oil level is okay; fill with same amount drained using new oil. If amount drained is less than 3.2 ounces, pour in 3.2 ounces of new refrigerant oil.
NO OIL LEAK; REPLACING COMPONENTS
If only the compressor is to be replaced, remove, drain oil, measure and reinstall an equal amount of new oil. If evaporator is being replaced, add 3 ounces of new oil. If condenser is being replaced, add one ounce.
LOSS OF REFRIGERANT OVER EXTENDED PERIOD
When a loss of refrigerant has occurred over an extended period of time and a component is being replaced to correct the leak, add an appropriate amount of refrigerant oil to the component.
SIGNS OF EXCESSIVE OIL LEAKAGE
If system has lost excessive oil, remove accumulator. Drain and measure oil. If more than 3 ounces is measured, replace the same amount of new oil as was drained. If less than 3 ounces is measured, add 3 ounces of new oil. Add and additional 2 ounces of new oil to compensate for that lost by replacing the accumulator (held in desiccant).
Note. If the exact oil charge is in doubt, drain and flush system. Add a new 6-ounce charge of refrigerant oil to the system.
NO OIL LEAK
Discharge system and change components as necessary. See SERVICING PRECAUTIONS at the beginning of this article. Add refrigerant oil to components as necessary.
OIL LEAK
- Slowly discharge system. Repair or replace faulty components. If equipped with a drain plug, remove plug, drain and discard oil. If not equipped with a drain plug, remove compressor from vehicle and pour oil out suction and discharge ports.
- Replace drain plug (if equipped). Add 1.5 ounces of new refrigerant oil through suction port. Use new gaskets or "O" rings when replacing suction and discharge lines.
COMPRESSOR FAILURE OR SYSTEM CONTAMINATED
If either situation exists, discharge system and remove compressor, receiver-drier and expansion valve. Clean expansion valve screen. Flush entire system. Install new compressor and receiver-drier. New compressors contain correct amount of oil. If installing overhauled compressor, add 1.5 ounces of new refrigerant oil through suction port.