Correction

Correction:
If a vehicle has been identified through DCS inquiry as being affected by this Service Action, proceed to check the air conditioning capacity label.

1. If this label shows a filling capacity of 975g or 1000g, it has been replaced before and the system has already been charged with the proper amount of 2.2 lbs. (1000g) of Freon(R). This correction was probably performed based on a customer complaint and the instructions published in the advance version of this bulletin.

DO NOT PROCEED ANY FURTHER. THIS VEHICLE HAS BEEN PREVIOUSLY REPAIRED.

2. If the label shows the original filling capacity of 2.64 lbs. (1200g), the air conditioning system must be evacuated and recharged.

Completely evacuate (recover) and recharge these vehicles with 2.20 lbs. (1000g) of R-12 refrigerant. Do not refill with the vehicle air conditioning label specified amount. The correct fill amount for the vehicles fitted with this smaller type condenser is 2.2 lbs (1000g). Use proper R-12 recycling/recovery equipment.

Note:
The system MUST be completely recovered and recharged to the above level. Attempts to "vent off" a portion of refrigerant from the system are grossly inaccurate, environmentally unsound, and illegal. The following procedure shall be followed to evacuate and recharge E36 vehicles affected by this Service Action. Note that a long vacuum time is not necessary, since the system is assumed not leaking and has not been opened.

1. Hook up manifold gauge set and R-12 recovery machine as per manufacturer's instructions. Open gauge valves and check system pressures. If no pressure exists in the system, the vehicle has lost refrigerant and the A/C system must be completely repaired and evacuated according to the repair manual before continuing.

2. Start the recovery cycle on the machine according to the manufacturer's instructions. The recovery cycle will typically shut off automatically after 13 inches of vacuum is reached on the system. Measure the amount of oil extracted from the air conditioning system.

3. Disconnect the recovery unit and connect the vacuum pump. (in some cases the pump is part of the recovery machine and this step does not apply.)

4. Turn on vacuum pump and vacuum system at 29.9 inches of vacuum (maximum capacity of vacuum pump) for 5 full minutes. Disconnect vacuum pump and add fresh refrigerant oil equal to the amount extracted in Step 2. Do NOT reuse old refrigerant oil. Follow equipment manufacturers procedure to add oil.

5. Connect R-12 charging station. Recharge affected E36 air conditioning systems with 2.20 lbs. (1000g) of R-12.

6. Remove charging station. Start vehicle and operate air conditioning with maximum cold temperature, maximum fan speed, recirculation off, and windows rolled down. Verify that A/C system pressures are normal with respect to ambient temperature and humidity.

7. To prevent future overfilling of the lower-capacity condenser, apply a new A/C Label, P/N 90 00 1 000 006, on the metal support above the passenger-side headlight. Clean any dirt or oil from this area before applying label. Remove old label prior to applying new label if possible. If the label proves impossible to remove without damaging paintwork, apply the new label directly on top of the original.

Note:
Although the new label specifies the correct fill capacity for the condenser style installed in these vehicles, the original label, as well as the original R-12 fill amount (2.64 lbs./J1200g) will have to be restored if the condenser is ever replaced. The smaller-capacity condensers will not be available from Parts.