Five key considerations for successful EV servicing
Compressor Installation Manual EN
Repair of car air conditioning or installation of car air conditioning parts should only be carried out by certified and trained mechanics.
- To remove or install a compressor, refer to the appropriate official vehicle repair manual.
- When handling and disposing of refrigerant, always follow local government regulations.
- To reclaim or charge refrigerant from the A/C unit, use certified equipment.
- To keep dirt and moisture out of the system, cap the open fittings immediately when disconnecting hoses or other parts.
- When tightening bolts and nuts always use the correct tightening torque according to the vehicle specifications.
- Always replace those parts referred to in the parts replacement table. For the correct conditions refer to repair procedures.
- Only use the DENSO recommended compressor oil as indicated on identification label of the compressor.
- When cleaning of the refrigerant system is required, use appropriate flushing equipment. For flushing conditions refer to ‘Refrigerant Cycle Flushing’.
- After installation it is important to follow the DENSO recommended run in procedure. For details refer to ‘Run in Procedure’.
REFRIGERANT CYCLE FLUSHING
The long life time of a compressor is only guaranteed when the correct amount of DENSO recommended oil has been used. If contaminated by foreign oil or additives, such as the wrong or too much UV dye, the refrigerant cycle must be flushed before new parts are installed. In case Leak Stop, imitation refrigerants or severe contamination are present, flushing is no longer sufficient and the complete system must be replaced. When flushing the refrigerant cycle we recommend the use of dedicated flushing equipment. The use of an A/C service station is not recommended.
Conditions for flushing are:
- Too much or wrong oil type.
- Too much or not approved UV leak dye.
- Unclear how much oil remains in the refrigerant cycle.
- Oil additives, (In case of leak stop flushing is NOT possible). All parts need to be replaced!
- Dirt in the refrigerant cycle, such as black residue. (In case of severe contamination flushing is not possible and all parts need to be replaced)
Always check the car manufacturer data if the oil quantity from the new compressor needs to be adjusted.
WHEN TO REMOVE OIL:
Refer to the conditions as described under repair procedure 1.
WHEN TO ADJUST OIL:
For some applications it is necessary to adjust the oil quantity when:
a) The same compressor part number is used for vehicles with single and dual evaporator cycles.
b) The compressor oil quantity differs from the car manufacturer data (see compressor identification label).
c) Following the required repair procedure 1, 2, 3 or 4.
Never add oil directly into the compressor. When applicable always add the oil in the condenser, receiver dryer or second evaporator cycle. To recognise which type of oil to use check the compressor identification label, either attached to the rear or side of the compressor.
Only use the original type of oil and never mix with other types or universal type oil. Mixing with other oils or using universal oil will reduce the lifetime of a compressor and can cause severe damage. When using other type of oils than specified, warranty is void.
RUN IN PROCEDURE
After installation of a new compressor it is important to follow the run in procedure described below. The purpose is to distribute compressor oil and start up lubrication in order to prevent damage directly after new installation.
- Set temperature to max cool.
- Switch blower to max speed.
- Start engine and keep engine rpm at idle.
- Switch A/C on for a minimum of 5 minutes. DO NOT INCREASE ENGINE SPEED!
- After 5 minutes all compressor oil, originally stored in the compressor, is transported through the system. Now it is safe to increase engine speed and test A/C.
To determine which repair procedure is applicable, first check the cleanliness of the refrigerant cycle. After removal of the old compressor check the suction port, discharge port and discharge hose. Depending on the situation found, refer to procedure 1, 2, 3 or 4.
Flushing is not required > adjust the oil quantity from the new compressor when necessary.
a) The system is clean.
b) The correct type of oil is inside the cycle.
c) The correct amount and type of UV-leak dye is used.
d) There are no other additives in the refrigerant cycle.
Installation guide: Refer to the parts replacement table to confirm correct parts to replace. Use the following calculation to confirm the correct amount of oil to remove from the compressor.
A = Total oil amount new compressor.
B = Oil amount drained from the old compressor.
C = Amount required to remove from new compressor.
Calculation to establish the correct oil amount to remove from new compressor: A-B=C
Flushing is required to remove too much or incorrect oil or not approved additives.
a) Incorrect oil or additives are found.
b) The refrigerant cycle is clean
c) No black or metal particles are found.
Installation guide: Refer to the parts replacement table to confirm correct parts to replace. Do not remove oil from the new compressor. Review car manufacturer data to check if it is necessary to adjust the oil quantity.
Flushing is required to remove dirt, black particles are found.
a) Black particles are found in the refrigerant cycle.
Installation guide: Refer to the parts replacement table to confirm correct parts to replace. Clean the remaining parts of the refrigerant cycle by flushing. Do not remove oil from the new compressor. Review car manufacturer data to check if it is necessary to adjust the oil quantity.
Flushing is not possible, replace all refrigerant cycle parts.
a) Black sludge and metal particles are found in the refrigerant cycle.
b) Leak Stop is found in the refrigerant cycle.
Installation guide: Replace all parts. Cleaning of the refrigerant cycle is not
possible. Do not remove oil from the new compressor. Review car manufacturer data to check if it is necessary to adjust the oil quantity.