Changes to Oil Charge for R12 Service A/C Compressors and Oil Handling Procedures. Saturn Saturn 1992

For 1990-2009 cars

# Changes to Oil Charge for R12 Service A/C Compressors and Oil Handling Procedures

Subject: | Service Information on Changes to Oil Charge for R12 Service A/C Compressors and Oil Handling Procedures

Models: | 1991 - 1993 Saturn S-Series vehicles originally equipped with R12 A/C systems

### Purpose

This bulletin provides information on changes to the oil charge for R12 service compressors. New service A/C compressors will contain 100cc of oil instead of 200cc. A/C compressor oil overcharge will result in reduced cooling capacity. Undercharge may result in premature component failure.

It is necessary that the A/C system maintains 200cc oil charge. In order to maintain the appropriate oil charge, refer to the oil measuring and handling procedures in this bulletin.

Important: Oil charge can be identified by locating the label on the rear of the compressor. The 100cc oil charged service replacement A/C compressor will read "100cc COMP/200cc SYS." The "100cc COMP" designation indicates that the compressor unit has 100cc of oil installed and the "200cc SYS" designation indicates the total A/C system requires 200cc of oil.

### Procedure

Important: The A/C compressor (P/N 21031410), which contains 100cc of oil, can be identified by locating the label on the rear of the A/C compressor. The 100cc oil charged service compressor will read "100cc COMP/200cc SYS".

The following information is contained in the Saturn HVAC Service Manual. However, it is reprinted here for your convenience.

#### Oil Measurement

Notice: Confirm the refrigerant recovery oil bottle on the refrigerant recovery station is empty prior to recovering refrigerant. If excessive oil is introduced to the A/C system, decreased A/C performance will result.

1. Remove the A/C compressor from the vehicle. (Refer to "Compressor" removal procedure in the "Service" section of the Saturn HVAC Service Manual.)
2. With the A/C compressor on a clean bench, install the high and low side A/C compressor oil drain adapters SA9149AC-6 and SA9149AC-5 on the low and high side ports.
3. Drain the oil into a clean dry container.

3.1. | Position the A/C compressor to drain from the high side port first.

3.2. | Move the A/C compressor to different positions to remove all oil possible.

3.3. | Turn the A/C compressor over to drain the oil from the low side port.

3.4. | Rotate the A/C compressor drive plate in both directions to remove the oil from the A/C compressor chambers.

3.5. | Stop oil draining when the oil coming from the low and high side ports becomes only drops.

3.6. | Measure and record the oil removed from the A/C compressor.

3.7. | Discard removed oil as all new replacement (service) A/C compressors come with 100cc of Saturn compressor oil installed.

4. Place the new A/C compressor on a clean work bench with the high and low side ports in an upright position.
5. With the A/C compressor high and low side ports in an upright position, slowly remove the high side cap retaining bolt to release nitrogen (N2 ) charge.
6. Remove the high and low side caps. (Install the high and low side shipping caps on A/C compressor removed from the vehicle, to prevent any oil from leaking out when the A/C compressor is being shipped.)
7. Install the oil drain adapters on low and high side ports of the new A/C compressor.

Important: Oil drained from the new A/C compressor should be drained into a clean, dry container and then reused.

8. Drain oil from the new A/C compressor into a clean, dry container.

8.1. | Position the A/C compressor to drain from the high side port first.

8.2. | Move the A/C compressor to different positions to remove all oil possible.

8.3. | Turn the A/C compressor over to drain oil from the low side port.

8.4. | Rotate the A/C compressor drive plate in both directions to remove the oil from the A/C compressor chambers.

8.5. | Stop oil draining when oil coming from the low and high side ports becomes only drops.

Notice: Additional NEW Saturn oil may be needed to obtain the amount of oil required for the next steps. However, be careful not to overcharge the A/C system with oil. An overcharged A/C system will result in decreased A/C system performance.

9. Add the recorded amount of oil drained from the old A/C compressor to the new A/C compressor through the high side port (measurement was obtained in step 3f).
10. Add the recorded amount of old oil recovered in the oil recovery bottle during refrigerant recovery process to the high side port.
11. Install the A/C compressor into the vehicle. (Refer to "Compressor" installation procedure in the "Service" section of the Saturn HVAC Service Manual.)

### Parts Requirements

21031480 Compressor Asm -- A/C

21030363 Oil -- A/C Cmpr

### Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for D4440 (replace Compressor Assembly), or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.