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Maybe your air conditioner has decided to quit or you would like to
change from the freon based a/c system of old. How do you go about it?
Where do you get the parts? Can you do it yourself? This article will
answer all of these questions.
The parts are readily available from Zip Products, Inc.,
8067 Fast Lane, Mechanicsville, VA 23111, (800) 962-9632. They now have
a complete R134A Conversion Kit along with any other a/c parts you may
need from compressors to valves. You can do most of the conversion
yourself. You will need a certified a/c repair shop to evacuate and
flush the system before the conversion. You will also need them to fill
the system with R134A. You can do the conversion yourself if you
understand how an a/c system operates in your Corvette and are a
competent home mechanic. If the extent of your mechanical ability is to
change the oil, do not try this project yourself. Leave it to the
professionals. Even if you are not doing this conversion yourself, this
article will help you to understand what is involved.
Our
Project 78 had a leaking compressor so we felt a new compressor and the
R134A changeover was in order. Now let's get that a/c EPA friendly and
working. |
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01: We called Zip Products and received the following:
The R134A Retro Kit with the correct ester oil, fittings and O-ring. A
new accumulator, orifice tube, new compressor and muffler and hose. |
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02: Start by taking your Corvette to a certified a/c
repair shop and have the system evacuated and flushed. After all of the
system is flushed, seal off any open a/c hoses or valves. To begin the
project, remove the hood. Remember to scribe a mark on each hinge. This
will make the hood re-alignment much easier. |
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03: The radiator overflow tank must be removed. This will give you access to the a/c evaporator area and hoses. |
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04: Remove the right lower splash shield. You will
have to remove the rocker panel moulding to gain access to the two
outer bolts. Removing this shield gives you access to the accumulator
and hoses.
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05: Disconnect the muffler and hose assembly from the compressor. |
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06: With the splash shield cover removed from the
bottom of the fender, reach up through the opening to loosen and remove
the accumulator and bracket from the evaporator. The hoses and
accumulator can now be pulled out through the splash shield opening.
The compressor can now be loosened and removed from its mounting
bracket. |
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07: Disconnect the evaporator line and pull out the
old orifice tube. You will need an orifice tube removal tool to
complete this step. These are available from most tool supply
companies. With the compressor removed, drain any oil that is left in
it. If you are converting from a freon system to a R134A system, the
freon compressor oil will not mix with the new ester oil used in the
R134A system. If you are installing a new compressor, as we are, this
is a safety precaution. Even though the new compressors are suppose to
have the correct oil in them, I would rather be safe than sorry. This
is why I recommend draining the oil. |
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08: Add the correct amount of ester oil to the
system. If your old freon system used eight ounces of oil, then you
must replace the oil in the system with 8 ounces of ester oil. Put 4
ounces in the compressor and the remaining 4 ounces in either the
accumulator/drier or the evaporator. NOTE: Cap the compressor opening
when you are done. |
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09: When installing the orifice tube, be sure that this end goes down into the line. |
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10: Slide the orifice tube into the evaporator line.
Make sure that it slides all the way down into the line so that the
male end of the line fits flush with the female end. |
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11: Install the compressor and adjust the belt
tension. A belt tension tool, available at most auto parts stores,
makes this a snap. |
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12: Place the correct R134A O-ring onto the muffler
and hose assembly and fasten this to the accumulator. Remember to use
only the R134A O-rings supplied. Fasten the mounting bracket onto the
accumulator. |
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13: Route the accumulator and hose assembly up
through the splash shield opening and mount it into place. Connect the
evaporator line to the accumulator. Remember to install the correct
O-ring. |
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14: Use a common tire valve tool to remove the
shrader valve in the muffler and hose assembly. This type of valve is
not compatible with the new R134A systems. This is why these valves
have to be removed. |
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15: Install the new 134A valve onto the muffler and hose assembly. |
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16: Wrap new insulating tape around the evaporator line and temp switch probe. |
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17: Place a new O-ring on the evaporator line and screw it onto the orifice tube line. Make sure the line fitting is tight. |
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18: Re-install the radiator overflow bottle onto the inner fender. |
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19: Place 2 new O-rings onto the back of the
compressor and install and tighten the muffler and hose assembly.
Disconnect the a/c compressor switch and move it out of the way. By
disconnecting the a/c compressor, there is no chance that you will
accidentally turn it on without being charged. |
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20: Remove the old shrader valve in the inlet tube assembly block and install the new 134A fitting. Tighten this fitting into place. |
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21: Route and install the muffler and hose assembly onto the condenser. Again remember to install a new O-ring. |
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22: Check all the fittings on the accumulator and
re-install the splash shield. Now go back and check to make sure all of
the hose and fitting connections are tight. |
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23: Align the scribe marks on the hood with the hinges
and tighten the hood into place. Lower the hood down slowly and check
to make sure all of the gaps are even. Check the hood latch operation
before you close the hood. If it is OK, close and open the hood a few
times to make sure everything works correctly. Now that everything is
installed, you are ready for a return visit to the certified a/c repair
shop to have the system charged with 134. The system should be
evacuated for approximately 30 minutes. After it is evacuated, charge
the system with 134 and check for leaks. If everything checks out, you
will be cool and EPA friendly.
NOTE: You will
notice that a R134A system is not as cold as a freon system when you
are sitting at an idle. This is because 134A needs air flowing across
the condenser to speed up cooling. If your system is not cold enough at
an idle, you can install an electric fan to help push air across the
condenser. |
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EPA Friendly Air Conditioning:
How to convert your Corvette's air conditioning to R134A
Source:
Zip Products, Inc.
8067 Fast Lane
Mechanicsville, VA 23111
(800) 962-9632
Parts List:
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