Work Instruction
Group: 83Date: December 1989
Number: 244b
(supersedes 244a)
SUBJECT:
REPLACING A/C HOSE ASSEMBLY (ONE-PIECE) ON COMPRESSOR
MODEL 201.034 (190E 2.3-16) MY 1986-87
Revision: Information in the Time Allowance was revised.
IMPORTANT!
Read through entire W.I. BEFORE performing any work on vehicle.
Procedure
A/C Hose Assembly Modification
Note:
The A/C hose assembly is a one-piece design and incorporates a muffler to reduce compressor-refrigerant noises.
1. Prior to performing any disassembly work, run the engine (ensure that vehicle is in Park/Neutral and emergency brake is on) and operate the A/C system via the push-button control in the console. Observe and note the appearance of the sight glass in the receiver-drier. This information is needed later for reassembly.
2. Drain freon from system. Release pressure slowly to conserve refrigerant system lubricating oil.
3. Remove air filter housing.
4. Remove coil ignition wire from the ignition distributor cap.
5. Remove and lay aside the ignition distributor cap (with wires attached).
6. Remove intake manifold assembly (complete).
7. Unbolt A/C hose assembly at A/C compressor.
8. Disconnect A/C hose at low pressure side of hose assembly from metal line (leading to expansion valve) (Figure 1). Disconnect the high pressure side of the A/C hose assembly from the condenser (Figure 2). Remove support clamp below fitting, if so equipped.
9. Loosen fuel tank filler cap to release any pressure. Unscrew fuel lines to fuel cooler. Discard return line. Close off connections. Immediately clean up any spilled fuel. Retighten fuel filler cap.
10. Remove A/C hose through the top of engine compartment.
11. Guide new A/C hose assembly into place through top of engine compartment.
12. Fasten A/C hose manifold to compressor.
Note:
Always use new O-rings at the compressor/hose manifold interface.
13. Connect high pressure side of A/C hose (to condenser) (Figure 2).
14. Fill 30 ccm of oil into the low pressure connection of A/C hose assembly and reconnect to the metal line (leading to expansion valve) (Figure 1).
Caution!
Additional refrigerant oil will be needed if additional components are replaced (ie: condenser, etc.). See service microfiche Tempmatic Model 201, job no. 83-520 for specific guidelines and oil fill quantities.
15. Install new fuel return line to fuel cooler (Figure 3)
16. Reinstall existing fuel feed line to fuel cooler (Figure 3).
17. Attach fuel return hose (arrow) to fitting on return line bracket and route hose to fuel distributor as indicated (Figure 4).
18. Reinstall intake manifold assembly and attach fuel return line bracket to manifold stud (Figure 5).
19. Replace receiver-drier and exchange the 20 bar pressure switch with a 16 bar pressure switch.
20. Evacuate and charge A/C system and check for leaks.
21. Reinstall all other parts in reverse order from removal.
22. Perform function check.