Refrigerant Oil

Calculation during
Compressor
Replacement

Study Guide
TMT: 100820

Dealer Education
 ©2008 Navistar, Inc.
4201 Winfield Road, Warrenville, IL 60555.

All rights reserved.

No part of this publication may be duplicated or stored in an information

retrieval system without the express written permission of
Navistar, Inc.

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 Refrigerant Oil Calculation During
Compressor Replacement

Welcome to this Navistar training program on Refrigerant Oil Calculation During

Compressor Replacement.

To receive credit for completing this program, you are required to take a post-test
on ISIS/Education/Service/Online Testing.
 Objectives

 Identify background information on

refrigerant oil level and its effect on system
operation when it is not properly maintained.

 Perform the procedure for adding oil into the

AC system during compressor replacement

* There is no audio for this slide.

2

Upon completion of this training you will be able to:

Identify background information on refrigerant oil level and its effect on system
operation when it is not properly maintained.

Perform the procedure for adding oil into the AC system during compressor
replacement
 Shop Safety Procedures

Before we begin inspection, diagnostics, and repair, keep in mind that proper
service techniques, environmental concerns and safety are the most important parts
of this process. Be sure to follow each warning, caution and note as they are
presented throughout this training program.

Warnings indicate procedures and safety measures that must be followed precisely,
and to avoid damage to the vehicle, equipment or components.

Cautions indicate procedure that you must follow exactly to avoid equipment or
component damage.

Notes indicate operations, procedures or instructions that are important for proper
service.
 Shop Safety Procedures

 Protect interior of
vehicle by using
 A paper floor mat
 Steering wheel
cover
 And seat covers.

When performing service work of any kind, always protect the interior of the vehicle
by using:

•a paper floor mat

•steering wheel cover

•and a seat cover.

 Shop Safety Procedures

 To prevent
personal injury or
death
 Make sure the
vehicle is parked on
a flat surface.
 Set the parking brake
and block the wheels.

Warning: Before beginning diagnostic or service procedures, always shift the

transmission to park or neutral, set the parking brake and block the wheels.
 Shop Safety Procedures

 To prevent
personal injury or
death perform
service in a well
ventilated, dry
area.

Warning: Always provide proper ventilation when operating an engine in an

enclosed area.
 Shop Safety Procedures

 Keep tools and

work area as clean
as possible.
 Clean connections
and fittings before
removing
components.

When working on the vehicle, keep the work area and tools as clean as possible.

Also, clean all connections or fittings before disconnecting or removing components.

 Shop Safety Procedures

 Use a suitable pan

to catch fluids.
 Plug all line and
component
openings.
 Know the location of
properly rated and
charged fire
extinguishers.

Use a suitable pan to catch any fluid when disconnecting components. All
component and line openings should be immediately plugged during removal and
remain so until re-installation to prevent contamination by dirt, moisture or other
foreign material. Be sure that you know the location of properly rated and charged
fire extinguishers.
 Shop Safety Procedures

 Safety glasses
 Hearing protection
 Chemical-blocking
nitrile gloves
 Know the location
of eye wash station.

Warning: When working on the vehicle, always wear safety glasses with side
shields, hearing protection, and chemical-blocking nitrile gloves. Be sure you know
the location of an emergency eye wash station.
 Introduction

 The correct volume of refrigerant oil in the

A/C system is critical for proper system
operation for the following reasons.

 Insufficient oil will result in compressor failure.

 Too much oil decreases cooling efficiency, resulting in

poor system cooling performance.

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The correct volume of refrigerant oil in the A/C system is critical for proper system
operation for the following reasons:

•Insufficient oil will result in compressor failure.

•Excessive oil decreases cooling efficiency, resulting in poor system cooling

performance.
 Introduction

 During normal A/C operation oil circulates

through the system with the refrigerant.

 Small amounts of oil are retained in each

component.

 To maintain the proper oil level in a system

that requires compressor replacement, the
following steps should be performed.

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During normal A/C operation, oil is circulated through the system with the
refrigerant, and a small amount is retained in each component.

In order to maintain the proper oil level in an air conditioning system that requires
compressor replacement, the following steps should be performed.
 Compressor Failures

 There are two different failures that would

cause compressor failure:

 Clutch failure

 Catastrophic failure

* There is no audio for this slide.

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There are two different failures that would cause compressor failure:
•Clutch failure
•Catastrophic failure
 Replacement due to Clutch Failure

1. Recover the refrigerant. Measure and record

the amount of oil removed during this
process.

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NOTE: The following procedure involves compressor replacement due to clutch

failure (non-serviceable clutch compressors only).

• Recover the refrigerant from the air conditioning system.

• Measure and record the amount of oil removed during this process.
 Replacement due to Clutch Failure

2. Remove the compressor. Drain, measure,

and record the amount of oil.

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Remove the compressor,

Drain, measure and record the amount of refrigerant oil.

 Replacement due to Clutch Failure

3. Drain and discard the shipping oil from the

NEW compressor.

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Drain and discard the shipping oil from the NEW compressor to be installed.

Refer to ISIS to confirm the proper type of refrigerant oil for the vehicle.
Replacement due to Clutch Failure

 Reference the Air Conditioning System

Specifications table in ISIS (manual s16019)
for the vehicle being serviced to confirm the
proper type of refrigerant oil.

 Oil calculation for clutch failure

Amount of Amount of oil
Total NEW oil added
oil drained + removed during
= to new compressor
from the old recovery
compressor process

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 Replacement due to Clutch Failure

4. Add NEW oil to the new compressor equal

to the amount drained from the old
compressor plus the amount removed
during the recovery process.
5. Install the compressor.

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Add NEW oil to the new compressor, equal to the amount drained from the old
compressor plus the amount removed during the recovery process.

Install the compressor.

 Replacement due to Clutch Failure

6. Evacuate the system.

7. Charge the system.
8. Conduct a system performance test to verify
proper operation of the air conditioning
system.

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Evacuate the system.

NOTE: Vacuum should measure between 750 and 1000 microns.

Refer to ISIS for the proper type and quantity of refrigerant for the vehicle and then
charge the system.

Finally, refer to ISIS to confirm the steps involved in the system performance test for
the vehicle and conduct a test to verify proper system operation.
 Replacement due to Catastrophic
Failure

 Catastrophic compressor failure requires the

replacement of the following components:

 The compressor

 The orifice tube or expansion valve

 The receiver drier, filter drier, or accumulator

* If the remaining components are to be reused, they must be

flushed and purged.

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The following information involves refrigerant oil calculation when the compressor is
being replaced due to catastrophic failure.

When faced with catastrophic compressor failure, the following components must
be replaced in addition to the compressor:

•the orifice tube or expansion valve

•the receiver drier, filter drier, or accumulator

NOTE: If the remaining components are to be reused, they must be flushed and
purged.
 Replacement due to Catastrophic
Failure

Procedural Steps

1. Recover the refrigerant from the system.

2. Discard the oil captured during this
process.
3. Disassemble the system.
4. If reused, flush and purge the condenser,
evaporator, and hoses.

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Follow this procedure when replacing a compressor due to catastrophic failure:

• Recover the refrigerant from the system and discard the oil captured during this
process.

• Disassemble the system.

• Referencing the procedures found in ISIS, flush and purge:

- the condenser
- the evaporator
- the hoses

NOTE: This is necessary only if the components are reused.

 Replacement due to Catastrophic
Failure

5. Replace either the receiver drier, filter drier,

or accumulator with a new one.

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Depending on how the vehicle is equipped, replace the appropriate component

(receiver drier / filter drier / accumulator).
 Replacement due to Catastrophic
Failure

6. Replace the orifice tube or expansion valve

with a new one.

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Depending on how the vehicle is equipped, replace the appropriate component

(orifice tube / expansion valve).
 Replacement due to Catastrophic
Failure

7. Drain and discard the shipping oil from the

NEW compressor.

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Drain and discard the shipping oil from the NEW compressor.

Refer to ISIS to confirm the proper type of refrigerant oil for the vehicle as well as
the full system quantity.
Replacement due to Catastrophic
Failure

 Reference the Air Conditioning System

Specifications table in ISIS (manual s16019) for
the vehicle being serviced to confirm the proper
type of refrigerant oil.

 Oil calculation for catastrophic failure

Total System 0.5 fl. oz. (oil
Refrigerant oil - film left in
=
Total NEW oil added
to new compressor
capacity compressor)

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 Replacement due to Catastrophic
Failure

8. Add NEW oil to new compressor (equal to

the total system capacity minus half an
ounce to compensate for the oil film left in
the compressor.)

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Add NEW oil to the new compressor (equal to the total system capacity minus half
an ounce to compensate for the oil film left in the compressor.)
 Replacement due to Catastrophic
Failure

9. Install the compressor.

10. Evacuate the system.
11. Charge the system.
12. Conduct a system performance test to
verify proper operation of the air
conditioning system.

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Install the compressor.

Evacuate the system.

NOTE: Vacuum should measure between 750 and 1000 microns.

Refer to ISIS for the proper type and quantity of refrigerant for the vehicle and then
charge the system.

Finally, refer to ISIS to confirm the steps involved in the system performance test for
the vehicle and conduct a test to verify proper system operation.
 Summary

 The correct volume of refrigerant oil is

critical for proper system operation

 Incorrect volume can cause compressor

failure and/or poor system performance

 There are two distinct procedures for

refrigerant oil calculation depending upon
the reason for compressor replacement

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In summary, the key points discussed in this training program are as follows:

The correct volume of refrigerant oil in the A/C system is critical for proper system
operation. An incorrect volume can cause compressor failure and/or poor system
cooling performance.

There are two distinct procedures for refrigerant oil calculation depending on the
reason for compressor replacement – clutch failure and catastrophic failure
 Conclusion

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This concludes the Refrigerant Oil Calculation During Compressor Replacement training
program.

You are now required to take a post test via ISIS / Education / Service / Online
Testing.