Operation CHARM: Car repair manuals for everyone.
Hosted by mcallihan.com
Home >> Saab >> 1986 >> 9000 L4-1985cc 2.0L DOHC >> Repair and Diagnosis >> Heating and Air Conditioning >> Service and Repair >> Retrofitting >> Retrofitting the A/C System From R12 to R134A >> Alternative 2

Alternative 2





WARNING: Wear protective gloves and eye protection and use extraction equipment when working with refrigerant. Position the extraction equipment at the service connectors on the A/C system and beside the outlet on the draining equipment's vacuum pump. If refrigerant comes into contact with skin or eyes, it may cause frostbite. Under no circumstances should the engine be started while work on the A/C system is in progress.

NOTE: When converting the A/C system, the usual practice in regard to the high-pressure and low-pressure side when draining and charging refrigerant is disregarded. Carefully follow the colour directions in the method description and on the diagram.

*** FOR ADDITIONAL INFORMATION NOT INCLUDED HERE, REFER TO TSB #08950610, DATED AUGUST, 1995 ***.

Materials
- Robinair draining and cleaning station for R12
- Robinair flushing kit 17560
- Solenoid valve set
- Refrigerant bottle with two cocks, gas and liquid
- R12 refrigerant (approx. 10 kg) for flushing
- 1 red high-pressure hose
- 1 blue low-pressure hose
- Adapter 82 92849, high-pressure side
- Adapter, oil plug, (Sanden compressor), (16)86 11 824
- Charging equipment for R134a
- R134a Refrigerant

Parts
A spare parts set, part number 74 96 466, has been developed for converting A/C systems from R12 to R134a. This set contains the following items:
- Dessicant container
- Pressure switch R134a
- Labels
- Service nipples, R134a
- Compressor oil (ester)





Schematic Diagram For Robinair With Automatic Control

Action
1. Check the operation of the A/C system as follows:
- Carry out a performance test. Refer to "Cooling Performance Test, A/C System". Testing and Inspection
- Carry out leak detection procedure Repair any system faults or damage in conjunction with conversion when the A/C system has been drained of refrigerant.
2. Drain the A/C system of refrigerant. Note the amount of compressor oil that is drained.
3. Repair any damage to the A/C system.
4. Remove the cover over the bulkhead space.
5. Remove the expansion valve's sensitive element and heat it in hot water to max. 50 °C (122 °F).
6. Connect the blue hose from the pressure gauge set to the service nipple on the flushing station.
7. Remove the Schrader valves and Schrader openers in the A/C system and on the equipment so that a free flow is obtained when flushing.
8. Connect one end of the blue low-pressure hose to the high-pressure side of the compressor.
9. Connect the other end of the blue low-pressure hose to the high-pressure side of the compressor.
10. Remove the compressor oil filler plug and fit the adapter supplied in the kit.
11. Connect one end of the red high-pressure hose to the solenoid valve kit.
12. Connect the other end of the red high-pressure hose to the compressor's oil filler connection.
13. Open the cocks on the bottle, start the draining station and set the solenoid valve set to AUTO. Set time as follows:
- The solenoid valve should be open a sufficiently long time for the sight glass to fill to at least halfway.
- The solenoid valve should be closed until the sight glass is empty other pressure has dropped by 1 bar.
14. When the oil is drained, foam and a film of oil are visible in the sight glass. Continue flushing until no more bubbles are visible in the sight glass. Rotate the compressor swash plate a couple of times during the flushing process.
15. Close the blue cock on the refrigerant bottle when the A/C system has been drained of oil after about 45 minutes. Set the solenoid valve set to position M (manual = open).
16. Drain the A/C system completely of all refrigerant.
17. Drain off the compressor oil from the draining station, note the amount and check that at least 90% of the total volume of oil has been removed.
18. Refit the expansion valve's sensitive element.
19. Change the dessicant container for the one supplied in the set.
20. Fit the three-stage pressure switch supplied in the set to the new dessicant container.
21. Refit the Schrader valves that will be needed for the service valves that are to be fitted.
22. Refit other components that have been removed.
23. Fill the compressor crankcase with 135 ml of the specially developed retrofit compressor oil. This oil is included in the spare parts set.
24. Refit the oil plug to the compressor.
25. Screw on the new service valves which are included in the set. The larger one is for the high- pressure side, the smaller one for the low-pressure side.
26. Connect up the equipment for R134a. Vacuum pump the A/C system and fill it with 950 grams of R134a refrigerant.
27. Remove the existing A/C labels and stick the "Retrofit" labels in their place. The labels are supplied in the spare parts set.
28. Carry out leak detection and performance testing.



pro multis · About Operation CHARM