Conversion of A/C System

Remove accumulator

Undo:

- ETF/KRU-valve at bracket. Remove locking clip and valve





- pipe connectors at the accumulator inlet and outlet.
- pressure switch connector and remove the pressure switch
- remove existing 0-rings. Note which size goes where.
- clamp holding the accumulator.

Lift Out accumulator with clamp.

Cap/plug open pipes to avoid moisture in the system.





Note:
In older cars or where the A/C system is fitted as an accessory, there is no ETF/ KRU-valve. If this is the case, remove the pipe at the firewall.

Location of orifice





- 1991 models and earlier: orifice is located in the evaporator inlet at the firewall.





- 1992 models: orifice is located in the high pressure pipe at the pipe junction on the side member.

Remove orifice

- Clean connection and surrounding body area thoroughly
- Undo nut on connection.





- Pull or work out the orifice (it is not threaded.)
- Take care not to break it and ensure that the entire unit is removed.

Inspect orifice filter:





Is the filter heavily clogged or heavily contaminated with metal particles? If so, the compressor may be in poor condition and should be replaced. (See illustration.)

As a rule of thumb, if more than three of the five orifice filter sections are clogged, (picture B) condition of the compressor oil should be inspected. If compressor oil is black, heavily contaminated or if compress or is dry, the compressor should be replaced. Picture A is normal.

The orifice should be not be reused once it has been inspected. There is a new orifice in the conversion kit.

If the compressor needs replacing:





A new compressor is filled with mineral oil. Drain this oil and replace it with all the ester oil (2OOml = 6.8oz) from the conversion kit. Save residual oil in can to lubricate 0-rings.

To replace the compressor, see Service Manual.

Install new orifice





If new orifice has a black 0-ring installed, discard the black 0-ring. Install new yellow, 0-ring, (inner dia. 6.7 mm) (use ester oil) on the new orifice.

- Install a yellow lubricated 0-ring, (inner dia. 10.8 mm) in the pipe joint at the firewall or side member.
- Install orifice and connect pipes.
- Tighten the nut on the joint to 12 Nm (9 ft. lb.)

Prepare new accumulator





Fill accumulator with ester oil on the inlet side.

Note:
If compressor was replaced in previous step, no ester oil is needed for the accumulator.

Save residual oil in can to lubricate 0-rings.




If there is no ETF/KRU-valve and pipe:

Additional kit 9145664-0 is required. Install new evaporator/accumulator pipe at evaporator side. Use new yellow lubricated 0-rings, (inner dia. 10.8 mm). (use ester oil residue in can) Hand-tighten nut. Place a new yellow lubricated 0-ring, (inner dia. 7.7 mm) on the filler pipe and connect to pipe between evaporator and accumulator. Hand-tighten nut.

Install new accumulator in the car

- Install, but do not tighten, clamp on accumulator. Use existing clamp if vehicle originally had an ETF/KRU-valve; otherwise, use clamp from additional kit.
- Install new yellow 0-rings, inner dia. 17.2 mm, (lubricated with ester oil residue in can) onto pipes to and from the accumulator.
- Install the accumulator clamp and accumulator on the car body. Hand tighten.





- Connect the accumulator inlet and outlet pipes. Hand tighten.
- Tighten accumulator clamp.
- Tighten pipe connectors (inlet and outlet) to 45 Nm (33 ft. lb.).
- Tighten evaporator joint to 27 Nm (20 ft.lb) if applicable.
- Using new 0-ring, inner dia. 8.9 mm, (lubricated with ester oil), fit the pressure switch onto the accumulator. Tighten to 3.5 Nm (31 in. lb).
- Connect pressure switch connector.

Install new R134a SAE filler valve

Use a new yellow, lubricated 0-ring, (inner dia. 7.7 mm) and tighten to 16 Nm (12 ft. lb.).





Install locking clip (included in conversion kit, p/n 9145660-8).

Note:
If filler pipe kit is being used, tighten joint on filler pipe to 16 Nm (12 ft.lb).

Check the system