VOLVO AC R134 refit kit instructions for the 700 series FAQ Home
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1. runs and the factory filling valve installed My car did not have this and need Sup kit 1 The basic kit has the new quick release valve that the R134a uses This illustration shows a car not equipped with the factory filling valve This can also occur if the A C was installed as an accessory In this case a Supplementary kit PN 9134032 3 is also required which replaces the pipe shown in the upper part of the illustration Exception 1 Requires in addition Supplementary kit 2 PN 9134344 2 for following models 6 27 2007 ACconvert 740 760 1987 Engine D24T Exception 2 Requires in addition Supplementary kit 2 9134345 9 for following models 780 1988 Engine B280F Conversion of A C system form R12 to R134a Retrofit Page 3 Page 4 of 18 The method described below is for installing Basic kit PN 9145660 8 This is in principle the basic method for installing Basic PN 9145661 1 or supplementary kits according to the first two pages Empty refrigerant from System This MUST be done by a licensed AC technician The free release of freon R12 is a federal offense Most places should do this for a small fee This also helps remove the oil and the freon trapped in the oil that could cause problems later on because of the incompatibility between the two type of freon Al Remove e Battery negative cable e Receiver A2 argiga Use rust inhibitor PN 1161422 92. ACconvert Page 1 of 18 VOLVO AC R134 refit kit instructions for the 700 series FAQ Home Volvo Maintenance FAQ for 7xx 9xx 90 Cars CFC Free A C Retrofit Kit for Pre 1993 Volvos ten Introduction Kit Contents Page 1 p Spi Eina aea A Se Dro j i i k n i r i k B Perr for purely information only No Warrantee is either given or implied Only people who have the correct equipment should Written by Dave Urban Caution This information is giving perform this task Years ahead of legislation Volvo first introduced CFC free air conditioning on all of its U S and Canadian 1993 model cars With the public s increasing concern about the environment Volvo released a retrofit kit for older model Volvos in the spring of 1993 The kit allowed Volvos with existing R12 freon based air conditioning systems to be converted to use a CFC free refrigerant Volvo was the first automobile manufacturer in the world to offer such a conversion kit for older model cars When I purchased my kit from my local dealer I was shocked to find that it did not include any type of instructions They were kind enough to fax it to me This is a web version of the instructions that I received I have added some of my own comments in italics This is not a job for the weekend mechanic It does require special tools Some of those tools can be used at the shop then the work done at the house Editor
3. When the instructions mention torque joint to 12 Nm this means to tighten until snug Don t overtighten the seal is made by the o ring not the threads Lubricate the o ring before installation with compressor oil use a backup wrench on all fittings and test with soap solution which will bubble in the presence of a leak after Supplementary Kit 1 mainly for cars not equipped e with factory fitted valve e with pipes or where pipe has e been removed as a service fix Supplementary Kit 2 e Shaft seal kit for cars equipped with Sandan Compressor http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert Page 2 of 18 Replaces 9145664 0 2 SD 510 508 The basic kit comes with New receiver Dryer R134a filler valve Ester Oil O rings R12 Filler permanent Caps Circlip Kit costs 9145660 8 57 00 Supplement 1 30 00 Go to Pagel 2345678 9 10 Volvo Maintenance FAQ for 7xx 9xx 90 Cars Contents of basic and supplementary kits from R12 to R134a Note that both the basic and supplementary kits can have different part numbers Some of the basic kits http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert may have different supplementary kits Use these pages a guidelines for the conversion of the A C system http oak cats ohiou edu ridgely retrokit ac_convert htm Page 3 of 18 Basic Kit 9145660 8 The illustration shows a car with the pipe
4. eceiver outlet with 45 Nm 33 ft Ibs fillter pipe Upipe with 16 Nm 12 ft Ibs e screws on the http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert http oak cats ohiou edu ridgely retrokit ac_convert htm Page 12 of 18 receiver clamp A17 Use a new O ring for the old pressostat lubricate with ester oil and install it on the receiver Compar size of the new O ring with the old one to ensure correst dimension Tighten the pressostat with 3 5 Nm 31 in lb A18 Connect the connector to the pressostat A19 Install the new SAE Filler valve for R134a Alternative 1 Use a new yellow lubricated O ring and install on the filler pipe U pipe Insatll SAE filler valve Tighten with 15 NM 12 ft Ibs Alternative 2 Use a new yellow lubricated O ring Install on the filler pipe U pipe Insatll SAE filler valve and circlip included in basic kit Tighten with 15 NM 12 ft lbs Conversion of A C system from R12 to R134a Retrofit Page 8 Inspect A C System Vacuum pump the A C system 6 27 2007 ACconvert qaiblit fi NIL fa tay WH ie i S Whey aqui r Page 13 of 18 Connect R134a recycling filling unit Start vacuum pumping and continue for at least 50 min Check that system keeps a vacuum The vacuum must not sink during a 4 min period This is with the vacuum turned off The recycling filling unit is not required
5. ely retrokit ac_convert htm Page 10 of 18 A13 Install expansion pip orifice Install a new yellow lubricated O ring on the new expansion pipe Compare size on the new O ring with the old one so they are the correct dimension Install a lubricated O ring in the pipe joint at the firewall or side member Install expansion pipe orifice Tighten the joint to the evaporator or the side member to 12 Nm 9 ft lbs A14 Top up the oil level in the new receiver Fill the receiver through the inlet side with ester oil supplied in the conversion kit 200ml Note If the compressor has been replaced and filled with ester oil in previous steps no additional ester oil is needed in the receiver A15 Remarks On older cars without pipes for ETF KRU valve Install pipes from Supplementary kit 1 PN 9134032 3 Finger tighten 6 27 2007 ACconvert Page 11 of 18 against the receiver Use lubricated O rings Connect filling pipe U pipe using a new lubricated O ring Al5 Install the following irs el q e Receiver in the Car S 2 e new lubricated O J Se rings at the joint between the evaporator and at ae the receiver outlet a i e pipe to evaporator and at the outlet Tighten by hand A16 Tightening an torques e the pipe between the evaporator and receiver 27 Nm 20ft lbs at the evaproator and 45 Nm 33 ft lbs at the Receiver the pipe at the r
6. for this step I used a standard AC vacuum from a R12 system and connected it to the other R12 charging port opposite the pressostat See arrow in the bottom picture and ran the vacuum for the 50 min http oak cats ohiou edu ridgely retrokit ac_convert htm Finalizing work A21 While evacuating the following work can be carried out Complete the light blue rectangular R134a RETROFIT label before the protecteive paper and carbon is removed Using ball point pen note e technician intials e dealer number if applicable or repar shop name city state e Date Carefully clean off the old r12 decal on the body work remove the carbon paper and stick the new light blue R134a RETROFIT lable over it Make sure the old label is 6 27 2007 ACconvert http oak cats ohiou edu ridgely retrokit ac_convert htm Page 14 of 18 completely covered Using mineral spirits clean top of accumulator then stick the round R134a RETROFIT decal on the receiver A22 Install the caps included in kit in the service valves which are no longer used Two on the compressor in sertain cases there are none on th ecompressor and one on the receiver see illustration below Use locking fluid PN 1161351 0 or equivalent on the caps A23 Refilling system with refrigerant On completion of vacuum pumping fill system with max 200 grams 0 44 Ibs refrigerant R134a Leakage testing after fillin
7. g Use leakage detector Repair any leaks When no leakage is detected fill with remainder of refrigerant R134a to the 6 27 2007 ACconvert http oak cats ohiou edu ridgely retrokit ac_convert htm amount stated below the link refers to a table of refrigerant capacities 740 2 4 1990 jlb 760 2 4 1987 lb f2 4 740 940 91 21 92 IIIb 940SE 760 960 8s _ I2 0 92 IIIb I applied the small amount of freon from a filler hose that I purchased at a local parts store where I purchased the freon cans One end screws onto the can and the other snaps onto the filler cap installed previously Hold the can upright so gas not liquid is sucked into the system I then opened the valve and let the vacuum suck the initial freon into the system and then the can provided enough pressure to trigger the pressostat switch to turn on the compressor I started the car and turned the A C system on to max cool and raised the idle and made the compressor suck the freon out of the can I have a 88 740 which requires 2 4 Ib or 38 oz The cans are 12 oz I put in 36 oz and saved the other can for a spare Once freon is added check for proper cooling and your done The remainder is if you could pump the correct amount in the system Page 15 of 18 6 27 2007 ACconvert Page 16 of 18 Verify Functions A24 Start e Engine e A C System Check that e Compressor starts and operates normally w
8. he firewall Then use Supplementary kit 1 PN 9134032 3 for installation Be sure to backup with a wrench both sides of the joint as no to twist the light metal A6 Plug all open pipe ends to prevent moisture from entering the system A7 Wipe clean around all connections that have been opened A8 Expansion pipe orifice location On model years 1991 and earlier 780 1990 the orifice is located in the receiver inlet at the firewall see arrow Note Make a point of noting how the orifice is sited in the pipe Refer to this and the next illustration Arrow B A9 On model year 1992 and later 780 1991 the orifice is sited in the High Pressure pipe at the pipe joint on the side member Arrow A http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert Note In some cases the work will be made easier if the pipe for the evaporator inlet 1s removed at the firewall the right side pipe as shown at Arrow B The O ring must then be replaced PN 3537503 9 A10 Remove expansion pipe orifice Clean the joint thoroughly Remove the union nut Pull or wiggle the expansion pipe out it is not threaded Take care not to break off the expansion pipe Make sure the whole unit is removed All Inspect expansion pipes opening s filter section If the filter is choked or there are a lot of metal particles in it refer to illus
9. ithout unusual noise e Incar air is cooled Stop engine Check for leakage with leakage detector Repair and leaks indicated This is my 1988 745 Volvo which has had the AC RETROFIT Here are some pictures of the retrofitted parts Looks about the same http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert Page 17 of 18 a EFi ller Pr ssostat m Reteiver Dryer j al FF Here is the filler cap and the filler cap opened Notice that the filler is a quick release connection You can also see the U joint from supplementary kit 1 Here is a picture of the notice stickers you put on the car NOTICE AC SYSTEM AETROFITTED TO Ria USE ESTEA OIL ONLY http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert Page 18 of 18 TERE ag Ti tE http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007
10. on all screw joints which are to be detached Allow the http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert Page 5 of 18 inhibitor several minutes to work before undoing screwed joints NEVER USE EXCESSIVE FORCE Note Under no circumstances use heat when removing I didn t do this step and all went fine I would say this is precautionary but not fully necessary A3 Detach e ETF KRU valve bracket Remove circlip and valve where installed pipe connections at the receiver inlet and outlet Be sure to use two wrenches when undoing connections so not to twist lightweight http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert Page 6 of 18 metal e the pressostat connector Remove pressostat this will be reused This is the low pressure cutoff switch Zf defective you can purchase one at the local parts store for about 12 Existing O rings note sizes Replace with new rings from kit on new equipment A4 Remove screws holding the receiver clamp A5 Lift out Receiver Conversion of A C system form R12 to R134a Retrofit Page 4 Remark On older cars or cars where the A C system was installed as an accessory there is no EFT KRU valve In this case remove the http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert Page 7 of 18 pipe see arrow at t
11. tration then the compressor may be in poor condition and need replacing with a new unit A rule of thumb If more than 3 of the 5 filter sections are clogged Fig B then the compressor oil http oak cats ohiou edu ridgely retrokit ac_convert htm Page 8 of 18 6 27 2007 ACconvert Page 9 of 18 should be examined If the compressor oil is black and heavily contaminated or if the compressor is dry then replace the compressor with a new unit Fig A shows an orifice that is normal After inspection the old orifice should be scrapped The conversion kit contains a new one A12 If the compressor must be replaced The new compressor unit as a replacement part is filled with mineral oil Empty the oil and replace with ester oil 200 ml 6 76 fl oz form the conversion kit Warning Do not fill Receiver with oil if replacing the compressor Only fill the compressor using the filler plug not through the inlet or outlet connections Note The O rings on the compressor inlet and outlet must always be replaced with new ones These Rings are not included in the kits and must be orded separatlly For compressor replacement refer to the Service Manual Section 8 82 88 Body Fittings Interior Climate Units 740 760 1982 19 Conversion of A C system form R12 to R134a Retrofit Page 6 http oak cats ohiou edu ridgely retrokit ac_convert htm 6 27 2007 ACconvert http oak cats ohiou edu ridg
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