Attachment III - Technical Information

INSPECTION





1. Make sure the A/C compressor is a VF2 type compressor by inspecting clutch hub face. If hub face is as shown in Figure 1 proceed to next step. If hub face is different than Figure 1, no Service Action is required. Return vehicle to customer.





2. Locate build label on side of A/C compressor. See Figure 2. Check serial number on build label.

^ If the serial number sequence is AP-0001 through AP-2180, the A/C compressor does not require replacement. Return vehicle to customer.

^ If the serial number sequence is AP-2181 through AP-3000, the A/C compressor must be replaced. Proceed to Service Procedure included in these technical instructions.

SERVICE PROCEDURE

1. Install memory saver, then disconnect battery negative cable.

2. Recover air conditioning refrigerant as follows:

^ Connect recovery station hoses to the vehicle gauge ports.

^ Turn on the recovery station.

^ Allow the recovery station to recover refrigerant from the system until the station pressure goes into a vacuum. On some equipment, the pump will be shut off automatically by a low-pressure switch in the electrical system. On other units, it may be necessary to manually turn oft the pump.

^ Once the recovery station has recovered the vehicle's refrigerant, close the station's inlet valve (if equipped). Then switch off the power supply.





3. Remove exhaust manifold bolt retaining suction line routing bracket. Refer to Figure 3. Position routing bracket away from its mounting.

4. Reinstall exhaust manifold bolt removed in previous step. Tighten to 23 Nm (17 lb-ft).

5. Remove suction line retaining clips, then remove suction line. See Figure 3.

6. Disconnect engine cooling fan electrical connectors.

7. Detach engine cooling fan wiring harness pushpins from cooling fan. Position wiring harness away from cooling fan.

8. Remove engine cooling fan retaining bolt, then cooling fan.

9. Disconnect A/C high pressure cut-off switch from the A/C compressor.





10. Remove A/C discharge line manifold retaining nuts, then separate manifold from A/C compressor. See Figure 4.

11. Remove serpentine drive belt.

12. Disconnect A/C clutch electrical connector.

13. Remove A/C clutch wiring harness from routing bracket. Position wiring harness aside.

14. NOTE: Position removed A/C compressor on workbench with ports facing up. This will prevent refrigerant oil from leaking out of the compressor. Remove A/C compressor mounting bolts, then remove A/C compressor from vehicle.

15. Disconnect two upper hoses from coolant degas bottle.

16. Remove coolant degas bottle mounting bolt and nut, then position bottle aside.

17. NOTE: The accumulator/drier and the accumulator/drier line are an assembly and must be removed together. Remove accumulator/drier assembly as follows:





^ Remove the accumulator/drier line clip, then separate the line from the evaporator fitting. See Figure 5.

^ Disconnect the A/C clutch cycling switch electrical connector located on top of the accumulator/drier.

^ Loosen the A/C line routing bracket nut, then swing the bracket away from A/C lines. See Figure 5.





^ Loosen the accumulator/drier mounting bracket screw. See Figure 6.

^ NOTE: Keep the accumulator/drier assembly as it will be drained of refrigerant oil later. Remove the accumulator/drier assembly from the vehicle. See Figure 6.

18. Remove condenser to evaporator line retaining bolts. These bolts are located in the right front corner of the engine compartment on the frame rail.

19. Remove condenser to evaporator line clip, then separate line from evaporator fitting. Refer to Figure 5.

20. Raise and support vehicle.





21. Remove lower radiator air deflector. See Figure 7.





22. Disconnect A/C discharge tine peanut connection, then remove A/C discharge line. Refer to Figure 8.

23. Disconnect condenser to evaporator line peanut connection. See Figure 8.

24. Lower vehicle.

25. Remove condenser to evaporator line from vehicle.

26. The evaporator and condenser must be individually flushed using Rotunda A/C Flushing Kit (014-00990). Refer to operating instructions included with the Flushing Kit, noting the following:

^ Circulate the flushing solvent through the evaporator or condenser in reverse direction of normal refrigerant flow for 15 minutes.

^ Circulate pressurized air (90-125 psi) through the evaporator or condenser in reverse direction of normal refrigerant flow for 30 minutes. Failure to continue air purge for the entire 30 minutes may result in residual amounts of flush solvent contaminating the A/C system.





27. Referring to Figure 9, install replacement orifice tube assembly as follows:

^ Position the condenser to evaporator line on a clean workbench.

^ Locate the orifice tube by the circular depression (A) in the metal portion of the condenser to evaporator line.

^ NOTE: Memorize orientation of the ends of the condenser to evaporator line so that they can be reassembled in the correct position. Remove original orifice tube from condenser to evaporator line by cutting a 2 3/4-inch section out of the line (B).

^ Remove burrs from both cut ends of the condenser to evaporator line.

^ Place compression nuts and ferrules onto both ends of cut condenser to evaporator line (C). Make sure the taper on ferrules is facing it's respective compression nut.

^ NOTE: the orifice tube will fit into the orifice tube housing only one way. Make sure the orifice tube is installed in its housing. Install the orifice tube if necessary.

^ Assemble the orifice tube housing assembly and cut sections of condenser to evaporator line. Make sure arrow on the orifice tube housing is facing the direction of refrigerant flow (D).

^ Orient ends of condenser to evaporator line so they are in their original positions.

^ Push each cut section of condenser to evaporator line into ends of orifice tube housing until it bottoms on the counterbore. Tighten compression nuts to 88 Nm (65 lb-ft) (E).

28. Position condenser to evaporator line into installed position.

29. Raise and support vehicle.

30. NOTE: Do not lubricate 0-ring before it is installed on peanut connection. Install new 0-ring on condenser to evaporator line peanut connection.

31. Lubricate new 0-ring with refrigerant oil.

32. Connect condenser to evaporator line peanut connection. Tighten connection to 8 Nm (71 lb-in).

33. NOTE: This new line will incorporate the discharge line and the suction line into one assembly. Install A/C discharge line assembly.

34. NOTE: Do not lubricate 0-ring before it is installed on peanut connection. Install new 0-ring on NC discharge line peanut connection.

35. Lubricate new 0-ring with refrigerant oil.

36. Connect A/C discharge line peanut connection. Tighten connection to 8 Nm (71 lb-in).

37. Install lower radiator air deflector. Tighten screws securely.

38. Lower vehicle.

39. NOTE: Do not lubricate 0-rings before they are installed. Install new 0-rings on evaporator end of condenser to evaporator line.

40. Lubricate above 0-rings with refrigerant oil.

41. Connect evaporator end of condenser to evaporator line to evaporator fitting. Secure connection with original clip.

42. Install condenser to evaporator line retaining bolts. Tighten bolts to 8-10 Nm (71-89 lb-in).

43. Drain and measure refrigerant oil from accumulator/drier as follows:

^ Obtain a clean container that can also be used as a measuring device.





^ Drill two (2)13 mm (1/2-inch) holes in the bottom of the accumulator/drier. See Figure 10.

^ Pour oil through drilled holes.

^ Record the amount of oil removed from the old accumulator/drier.

44. Fill replacement accumulator/drier with correct amount of refrigerant oil as follows:

^ Add same amount of refrigerant oil plus 60 ml (2 ounces) to the A/C discharge (suction) line port.

45. Install accumulator/drier into its mounting bracket. Route line toward evaporator.

46. Tighten accumulator/drier bracket retaining screw securely.

47. NOTE: Do not lubricate 0-ring before they are installed. Install new 0-rings on evaporator end of accumulator/drier line.

48. Lubricate new 0-rings with refrigerant oil.

49. Connect evaporator end of accumulator/drier line to evaporator fitting. Secure connection with original clip.

50. Swing A/C line routing bracket back into position. Tighten nut to 6-8 Nm (54-71 lb-ft).

51. Connect NC clutch cycling switch electrical connector.

52. Position degas bottle back into its installed position. Tighten bolt and nut to 10 Nm (89 lb-in).

53. Connect two upper hoses to coolant degas bottle.

54. Drain and measure refrigerant oil from VF2 compressor as follows:

^ Obtain a clean container that can also be used as a measuring device.

^ Rotate the compressor shaft by hand six (6) to eight (8) revolutions while pouring the oil from the compressor ports.

^ Record the amount of oil removed from the old compressor.

55. Remove the following components from the VF2 compressor:

^ Clutch hub bolt

^ Clutch hub

^ GShims

^ Snap ring

56. Assemble FS-10 compressor as follows:





^ NOTE: Field coil electrical connector must be positioned in the upward position. Using Field Coil Replacer (T91L-19623-CH), Coil Pressing Tool (T89P-19623-EH) and 2-Jaw Puller (D80L-1002-L), install new field coil on the compressor. Press on field coil until it bottoms out on compressor. See Figure 11.

57. Install new compressor pulley on compressor. Retain pulley using original snap ring.

58. Install original clutch hub shims and new clutch hub.





59. Install original clutch hub bolt. Using Compressor Clutch Holding Tool (T94P-19703-AH), tighten clutch hub bolt to 13 Nm (10 lb-ft). See Figure 12.

60. Using feeler gauge, measure air gap between A/C clutch hub and A/C clutch pulley mating surface at three equally spaced locations.

61. If measurements taken are not within .35-.85 mm (.014-.033 inch), air gap will need to be adjusted. If measurements taken are not consistent with each other, check for damaged clutch pulley or clutch hub.

62. To adjust air gap, proceed as follows:

^ Remove A/C clutch hub.

^ Remove or install necessary shims to bring clutch hub air gap within specified limits.

^ Install A/C clutch hub. Tighten hub bolt to 13 Nm (10 lb-ft).

^ Recheck air gap measurement. Readjust as necessary.

63. Fill A/C compressor with correct amount of refrigerant oil as follows:

^ If the amount of oil drained from the old compressor is between 85-142 ml (3-5 ounces), pour the same amount as was drained, plus one (1) additional ounce, of clean refrigerant oil into the new compressor.

^ If the amount of oil drained from the old compressor is greater than 142 ml (5 ounces), pour the same amount of clean refrigerant oil into the new compressor as was drained.

^ If the amount of oil drained from the old compressor is less than 85 ml (3 oz), pour 85 ml (3 ounces) of clean refrigerant oil into the new compressor.

64. Using new mounting bolts, install A/C compressor. Tighten bolts to 30 Nm (22 lb-ft).

65. Connect A/C clutch electrical connector and install harness in wiring bracket.

66. Install serpentine drive belt.

67. NOTE: Do not lubricate 0-rings before they are installed. Install new 0-rings on back of A/C compressor where discharge manifold is mounted.

68. Lubricate new 0-rings with refrigerant oil.

69. Using supplied bolt, connect A/C discharge line manifold to the A/C compressor. Tighten bolt to 20 Nm (15 lb-ft).

70. Connect A/C pressure cut-off switch.

71. NOTE: Do not lubricate 0-rings before they are installed. Install new 0-rings on accumulator end of A/C discharge line.

72. Lubricate new 0-rings with refrigerant oil.

73. Connect accumulator end of A/C discharge line to the accumulator. Secure connection with original clip.

74. Install engine cooling fan. Tighten retaining bolt to 10 Nm (89 lb-in).

75. Connect engine cooling fan electrical connector.

76. Route engine cooling fan wiring harness. Make sure pushpins are secured in place.

77. Connect battery negative cable, then remove memory saver.

78. Evacuate and recharge A/C system.

79. Test A/C system for proper operation.