Compressor Installation

Compressor Installation Instructions

WARNING: This compressor may be under pressure. To avoid possible injury, wear eye protection and slowly remove shipping caps or plate to release pressure. Compressor will not rotate until pressure is released. If equipped with a switch port plug, do not remove the snap ring until pressure is released. Do not test clutch operation with an alternate power source as internal diode damage may occur voiding compressor warranty.

Compressors are pre-labeled to identify oil charge per below:

• Yellow /Orange label = Drain oil and add per OE specification
• Pink label = Pre-charged w/ 3 oz of R134a PAG oil
• Green label = Pre-charged w/ 3oz PAG oil for R1234yf

Servicing a mobile climate control system is a complicated process requiring special tools and access to technical information. If you are not familiar with the following processes and procedures, it is advisable to seek the expertise of a qualified professional technician. Proper A/C performance is dependent on all systems performing correctly. It is important to replace or thoroughly clean the entire system to ensure a successful compressor replacement. High voltage compressor systems are very dangerous and can cause severe burns and electric shock that may result in serious bodily injury or death. (It is recommended that the installation of high voltage compressors be performed only by a qualified automotive technician with knowledge of the vehicle manufacturer’s latest service information and repair manual procedures.)

Follow all Federal, State and Local Regulations. Always Practice Safety First!

• Disconnect Battery
• No smoking
• Wear eye protection
• Work in a well-ventilated area
• Wear skin protection (gloves)
• Recover refrigerant before making repairs

A Clean A/C System is Imperative

When a compressor fails, tiny internal particles mix with oil and spread throughout the entire system. This contaminated oil, as well as moisture and other corrosives must be removed to avoid premature failure of the replacement compressor and related components. Clean the entire system thoroughly with an approved A/C cleaning agent and / or replace the contaminated parts. Compressed shop air alone does not remove contaminants.

Two methods found effective in removing oil and contaminant particles are as follows:

1. Liquid cleaning with an approved A/C cleaning agent. Flushing with Dura II flush solvent or similar non-oil-based flush designed specifically for automotive A/C use, is a proven method to clean A/C system components when used with a flush cylinder and pressurized air.
2. Closed loop flushing with a power flush machine and the machine manufacturer’s approved solvent is an effective method to clean A/C system components. This cleaning method is utilized by several major OE service providers.

Note: Most modern condensers in vehicles built after 2002 are difficult, if not impossible, to thoroughly clean/flush and must be replaced. Failure to do so may void warranty.

Replace the Filter Drier or Accumulator

All Filter Driers and Accumulators contain a desiccant material. This material is designed to absorb the moisture that has seeped into the A/C system. Moisture in an A/C system can form corrosive contaminates that will cause rapid system failure. It is very important to remove all moisture from the A/C system before charging. (Remove shipping caps just prior to installation.)

Replace or Inspect the Control Devices

The orifice tube is a refrigerant control and filter device for accumulator systems, and should always be replaced to ensure proper refrigerant and oil flow through the system. The thermal expansion valve is the refrigerant control device for systems using a receiver/drier. It should be examined and replaced, if found to be contaminated.

Proper Evacuation

The A/C system must be free of moisture and air to work properly. Removing the air and moisture with an A/C vacuum pump for a minimum of forty-five minutes is necessary to deliver a proper repair and long-lasting A/C performance.

Lubrication

The main mechanical component in the A/C system is the compressor, and adequate lubrication is critical. If oil or refrigerant charge is incorrect, internal damage to the compressor will occur! For the proper lubricant type & amount, refer to the under-hood decal, an O.E. service manual, or via application lookup at www.4s.com\eCatalog and selecting Compressor Lubricant. Note: R1234YF PAG oil is reverse compatible with R134a refrigerant and is a suitable replacement.

To ensure proper compressor lubrication, for compressors without an oil port, add half the required system oil in the suction side port. Turn the compressor shaft as the oil is added to prevent slugging. For compressors with an oil port, remove the oil port bolt and add half the required system oil. The remaining amount of required system oil should be added in the accumulator or evaporator on the low side of the system.

To ensure that the front seal is lubricated and does not leak, after the oil is added, the compressor must be placed or held with the front seal/clutch face down for 1 to 3 minutes, to allow oil to coat the seal. If this seal is not lubricated before installation, refrigerant may leak.

Use only the recommended Refrigerant Type and Amount

As technology has evolved, it is very important to check the manufacturers recommendation for refrigerant, oil type and amount. They are not all the same, some of the same applications may have two different types of refrigerants and oil, dependent on the compressor. The correct oil type and amount of charge is critical for system operation as the refrigerant carries the lubricant throughout the system. Specifications can be found on the under-hood decal, an O.E. service manual, or via application lookup at www.4s.com\eCatalog and selecting New or Reman Compressor. Note: R1234YF PAG oil is reverse compatible with R134a refrigerant and is a suitable replacement.

Compressor Rotation (Remove shipping caps prior to rotation)

Using a spanner wrench with the hoses connected, rotate the compressor shaft at least 10 revolutions prior to starting the engine. This will pump the excess liquid lubricant out of the compressor cylinders and into the system.

Compressor Clutch Operation

Compressor clutch operation is tested at time of manufacture. If necessary, a volt meter may be used to verify proper coil voltage of (11.5 to 13v). Clutch gap is measured for proper clearance and set to OE specifications. Be sure and check hub to pulley clearance prior to install. Clutch gap specifications can be found at www.4s.com under Technician Resources.