How to Repair Auto Air Conditioning Parts

How To Repair Auto Air Conditioning

It is always recommended that all auto parts are installed by a licensed mechanic. The

Videos and articles are here to give that little bit of extra knowledge.

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What is an Air Conditioning System?

• Automotive AC systems are very straight forward in their purpose. That purpose is to cool the air that is moving through the cabin of a vehicle. This result is achieved by blowing the air entering the cabin over a cooled surface (evaporator) which transfers the heat from the air to the coolant liquid that is flowing through the unit.

• The process begins with the pumping of a mixture of specialized oil and Freon through the system. The compressor is the unit responsible for creating this movement, after the fluid leaves the compressor is passed through the filter (Drier) and any debris that is suspended in the mixture will be captured. Now the compressed fluid (which carries a lot of heat) is passed through the condenser which is a unit that expands the fluid so that there is as much surface area where air can pass by. The passing air will pull the excess heat out of the fluid and cool it so it can perform its job. Next the fluid passes through the expansion device where the lines that carry the fluid expand, this allows the fluid to cool even further. Finally the fluid now travels through the evaporator where the heat from the air is absorbed again and the whole process starts over.

• The ability of the system to cool is very dependent on the temperature of the air around the system and can give varying results in times of extreme heat. Needless to say that on a 100 degree day the cooling will not be as effective as on a cooler day.


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How to Install A/C Compressor?• The most common failure of

replacement compressors is foreign material from a previously failed compressor. The system must be flushed and parts that can’t be flushed must be replaced. If debris remains, the system will clog and starve the compressor of refrigerant and oil, causing it to also fail.

• Air conditioning systems are well known for leaving dirt, debris and other contamination inside the condenser, the drier, the evaporator and even the lines. Failure to replace the drier (and other contaminated parts) and remove ALL contamination will destroy your part and void your warranty.





AC Accumulator / Orifice Tube System Layout

• The accumulator (located on the “suction” or “low-pressure side”) is designed to remove debris and moisture from the AC system, as well as prevent any remaining liquid refrigerant from returning to the compressor.

• The orifice tube meters a fixed flow of refrigerant to the evaporator. This system uses a thermostatic switch or “pressure switch” to cycle the compressor clutch to control the evaporator temperature.


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AC Basic Processes• Automotive AC systems are very straight forward in their

purpose. That purpose is to cool the air that is moving through the cabin of a vehicle. This result is achieved by blowing the air entering the cabin over a cooled surface (evaporator) which transfers the heat from the air to the coolant liquid that is flowing through the unit.

• The process begins with the pumping of a mixture of specialized oil and Freon through the system. The compressor is the unit responsible for creating this movement,. Aafter the fluid leaves the compressor it is passed through the filter (dDrier), and any debris that is suspended in the mixture will be captured. Now the compressed fluid (which carries a lot of heat) is passed through the condenser which is a unit that expands the fluid so that there is as much surface area as possible where air can pass by. The passing air will pull the excess heat out of the fluid and cool it so it can perform its job. Next the fluid passes through the expansion device where the lines that carry the fluid expand,expand; this allows the fluid to cool even further. Finally the fluid now travels through the evaporator where the heat from the air is absorbed again and the whole process starts over.





AC Basic Processes• Automotive AC systems are very straight forward in their

purpose. That purpose is to cool the air that is moving through the cabin of a vehicle. This result is achieved by blowing the air entering the cabin over a cooled surface (evaporator) which transfers the heat from the air to the coolant liquid that is flowing through the unit.

• The process begins with the pumping of a mixture of specialized oil and Freon through the system. The compressor is the unit responsible for creating this movement,. After the fluid leaves the compressor it is passed through the filter (Drier), and any debris that is suspended in the mixture will be captured. Now the compressed fluid (which carries a lot of heat) is passed through the condenser which is a unit that expands the fluid so that there is as much surface area as possible where air can pass by. The passing air will pull the excess heat out of the fluid and cool it so it can perform its job. Next the fluid passes through the expansion device where the lines that carry the fluid expand, expand; this allows the fluid to cool even further. Finally the fluid now travels through the evaporator where the heat from the air is absorbed again and the whole process starts over.



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How To Install AC Speed Sensor

• When the original (old) compressor has a Speed Sensor, reuse the original sensor from the old compressor by following these simple steps;

• 1. Remove the sensor hole cover and pull out the plug using the Plug Remover Ring (supplied) or pliers, as shown in the following illustrations.

• Warning: Compressor is pressurized! Use caution when removing sensor hole cover.

• Warning: Avoid oil loss from sensor opening. Add oil through sensor opening, if needed. Excess or insufficient oil can cause compressor failure and will void the warranty.

• 2. Reuse the original sensor from the old compressor and install it in the sensor hole of the new compressor.




AC Compressor Diagnosis

• The compressor can fail in a number of ways in an AC system, sometimes an AC system stops working for reasons besides the compressor. The above breakdown is provided by Sanden who is a major manufacturer of AC compressors. They are the OEM supplier for many automotive companies and have been in business for many years. The chart provided is a great little short cut for determining the issue that is facing a failing AC system.

• This is not an official install or instructional guide and BuyAutoParts.com is not responsible for any damage or injury that can occur during these procedures.




AC System Compressor Common Issues for Replacement

• An AC compressor defect is blamed for failure in the AC system more often than it deserves. The fact of the matter is that only about 3% of the time a compressor defect if the real cause of failure. Contamination of the system or lack of refrigerant is the most common cause of failure and many times the compressor is still functioning properly when the system has failed.

• There are a few easy steps to follow to be sure of compressor failure before it is removed:

• - Is the compressor rotation smooth?• - Is the field coil receiving greater than 11.5 Volts?• - Is the field coil resistance between 2.8 and 4.4 ohms?• - Is the compressor capable of producing 350 PSI or more?• The answer to these questions will determine if the

compressor needs to be replaced. This is not an official install or instructional guide and BuyAutoParts.com is not responsible for any damage or injury that can occur during these procedures




AC Lead Connection Install - Page 1

• When the Lead connection in a new compressor is different than the original it can be modified to fit. First disconnect the battery on the car and then splice in the old connector onto the new compressor. The preferred method is to solder the electrical connections and use shrink wrap tubing around it to protect the connection.




AC Lead Connection Install - Page 2

• When the Original compressor has a single lead wire plus a second ground the new compressor can be adapted with a service kit.




AC System Contamination and Flush

• Contamination in an AC system can build up and create problems with many key components. A proper flush of the system is key for regular life of AC components. Shown on the left side is a clean orifice tube and the same unit from a dirty system, if this debris is not cleaned out correctly it will fail quickly.







AC System Oil Levels

• It is important when you are installing a new compressor or any new parts in your A/C system, that you add the correct amount of oil. Adding the correct amount of oil to the A/C system, is just as important as putting quality replacement parts in your vehicle. Oil circulates with the refrigerant during operation, but during off periods the oil will settle in the components of the A/C system, like the evaporator and suction lines. If you add too much oil to the system and it begins to pool in places that it should not, it can cause serious issues in your A/C system. Too much oil in a system can coat the inner walls of the evaporator and condenser coils and diminish their ability to absorb or dissipate heat.

• There are a few different ways you can check to find out how much oil needs to be put into the A/C system. The first place to look is on the tag of the A/C compressor. There should be info on the A/C compressor telling you exactly how much oil you need to add to the system. If you cannot find the information on the compressor then you can always visit our website, and view our Reference Guide in our How To section (just click the link to be taken to the correct page). However, the easiest way to tell EXACTLY how much oil needs to be in your specific A/C compressor is to drain the old compressor and measure the amount of oil that comes out. All you need to do is fill the new A/C compressor with exactly the same amount that you drained out of the old A/C compressor.

• Remember that releasing refrigerant into the atmosphere is against the law. When adding oil to an A/C compressor you must first evacuate the system with a recovery machine. This captures the refrigerant and does not allow it to escape into the atmosphere. Please note that this is not an official install or instructional guide BuyAutoParts.com is not responsible for any damage or injury that can occur during these procedures. We always recommend that you have your A/C system serviced by a licensed mechanic.


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Effects of Refrigerant Loss

• The compressor is the most important part of the AC system but it can only function correctly if cooled properly. The oil in the system plays a roll much larger than just lubrication it also cools the compressor,. When the oil level drops it also means less cooling for the compressor. The lower the oil level drops the more damage that is done to the compressor. The lower the oil level drops the more damage that is done to the compressor. When the operating temperature raises the internal damage also increases.

• The oil will show signs of corruption before failure will occur and if seen soon enough the problem can be solved. The oil should be clear when it is being used in the system. As the amount of oil in the system lowers the heat raises and begins to burn the oil, burnt oil will be darker and darker as the damage increases. Once the source of the leak is found and the oil swapped for new, future problems may be averted.






Sanden AC Compressor

• Proper handling of sanden ac compressor freon is a must, Before removing any AC lines be sure that all pressure has been drained from the system. Never vent Freon into the atmosphere it must be captured by freon recycling equipment. Types of freon should never be mixed in the same piece of equipment.

• When handling freon gloves and eye protection should be worn, freon can cause frost bite or blindness. Keep freon away from open flames as it can create poisonous gas in the presence of flame.

• Do not use compressed air in an AC system to avoid contamination of the AC system. Sanden ac compressors will carry a warranty if the refrigerant follows SAE standards.


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Sanden AC Compressor Guide – Converting to R134

• Sanden AC compressor units are designed for specific types of refrigerant, swapping over to R134a will require the change of all internal parts of the system. It is not recommended that compressors designed for R12 are used with an R134a system. To do the change from R12 to R134a cycle the system and then capture all the R12 with proper equipment. Be sure to drain all of the mineral oil out of the entire system before beginning the retrofit.





Sanden AC Compressor Converting to R134a Page - 2

• When converting the AC system from R12 to R134a the whole system will need to be completely drained before the system is evacuated. be sure to pull a vacuum for at least 30 min before recharging the system with the new oil and freon for the system. Be sure to remove all the tags and stickers that indicate R12 so that in the future there will be no chance of the incorrect freon or oil being used.




Sanden AC Compressor Converting R12 system to R134a - Page 3

• Be sure when charging the AC system that you use about 5% less Freon per volume due to the change to R134a. In some cases extra capacity will need to be added to the system to achieve desired cooling, such as a cooling fan or larger condensing unit.




Drier Expansion Device System Layout

• The receiver-drier is located on the discharge, or high pressure, side of the A/C system. The drier, which can also be referred to as an accumulator, is designed to remove debris and moisture from the system as well as store a certain amount of refrigerant cycling through the system. If you call into Buy Auto Parts to buy a drier, you may hear our sales representatives refer to it as an accumulator/drier. While the two are slightly different from one another, if you don’t have one then you most certainly have the other and either way we are going to sell you the correct part. The drier receives refrigerant from the condenser. If you are looking to identify the drier in the A/C system, it can be found adjacent to the condenser or somewhere in line before the expansion valve.

• The drier acts as a filter to the A/C system. There is a desiccant element inside the drier that absorbs the moisture from the refrigerant. It is crucial that the moisture be removed from the system because it can be extremely damaging to the components inside your A/C system. The accumulator is found on the low side of the A/C system, at the outlet of the evaporator. It performs the same function as the drier. If any liquid escapes from the evaporator then the accumulator captures and stores that liquid. The accumulator also implements a desiccant element for absorbing moisture.

• When you are replacing your compressor or any other components in the A/C system for that matter, it is a good idea to replace the accumulator/drier. For more information on why you should change the drier when you change the compressor, please see our blog post by clicking here.




Sanden AC Compressor Models and Nomenclature

• A quick understanding of the sanden ac compressor number and types. Sanden ac compressor units are some of the most reliable AC compressors on the market and understanding the terminology of how to purchase the correct one is vital. R-12 sanden ac compressors use a specific numbering system and the R12 sanden ac compressors use "SD" to signify the Sanden name. Then the units have a 3 digit code such as 709 for the R-12 sanden ac compressors.

• The Sanden compressors that are designated for the R-134 freon use a slightly different code then the R-12 sanden compressors. The code is easy to determine and follow a code like SD7H15HD can be broken down into its parts. The SD stands for sanden the maker of this air conditioning compressor. The 7 is the number of cylinders in the sanden compressor, H stands for the port location (H if it is on the head and B if it is on the block) the 15 is the displacement in cubic centimeters. The HD stands for heavy duty and there can also be SHD for sealed heavy duty clutch.






Saturn Hose Installation Instructions• Drain Refrigerant• Remove discharge hose assembly and remove • Remove short suction tube from compressor and suction

hose• remove compressor, retain mounting bolts, belt and

manifold bolts to be reused• Flush system• Change drier with new one provided • Install compressor that was provided in the kit• Install new manifold with new seals provided • check clearance to exhaust, engine belt and frame. • Using the wire tie provided, tie the compressor clutch wire

away from the belt after connecting• Evacuate and charge with R-134A to the manufacturer's

original specifications. The scroll type compressor will have lower suction pressure than the original compressor had.




Saturn L Series Hose Notes

• The male fitting bolts to the condenser after the original discharge hose has been removed and discarded.

• There is a short suction tube that is removed from the compressor and suction hose and discarded. The female end if the manifold provided is then bolted to the suction hose.

• The manifold block mounts to the compressor.




How To Repair Auto Air Conditioning

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