Changes to Oil Charge for R134a Service A/C compressors and Oil Handling Procedures

This bulletin provides information on changes to the oil charge for R-134a service compressors. New service A/C compressors will contain 65cc of PAG oil instead of 150cc. 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 150cc or 200cc oil charge, depending on the model year of the vehicle being serviced. In order to maintain the appropriate oil charge, refer to the oil measuring and handling procedures in this bulletin.

Important: 1994 - 1996 Saturn vehicles built before and including VIN TZ251965 that have factory air conditioning contain a total system oil charge of 200cc PAG. Vehicles built after and including TZ251966 that have factory air conditioning have a 150cc total system oil charge.

Important: PAG oil charge can be identified by locating the label on the rear of the A/C compressor. The 65cc PAG oil charged service replacement A/C compressor will read "65cc COMP/150cc SYS." The "65cc COMP" designation indicates that the compressor unit has 65cc of PAG oil installed and the "150cc SYS" designation indicates the total A/C system requires 150cc of PAG oil. This service compressor will service both 150cc or 200cc PAG oil systems.

Important: A/C compressors available after April 1998, which contain 65cc of PAG oil can be identified by locating the label on the rear of the A/C compressor. The 65cc PAG oil charged service replacement A/C compressor will read "65cc COMP/150cc SYS."

The following information is contained in the "HVAC" service manual. However, it is reprinted here for your convenience.

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 vehicle. (Refer to "Compressor" removal procedure in the "Service" section of the "HVAC Service Manual.")



2. With the A/C compressor on a clean bench, install high and low side A/C compressor oil drain adapters SA9149AC-6 and SA9149AC-5 on low and high side ports.



3. Drain oil into a clean dry container.

3.1.	Position the A/C compressor to drain from 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 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 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 65cc of Saturn PAG 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 caps on the 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 the low and high side ports of the new A/C compressor.

Notice:  PAG oil drained from the new A/C compressor should be drained into a clean, dry container and used immediately. PAG oil absorbs moisture from the air. Failure to close the A/C system or cap the container that the PAG oil is in will result in moisture contaminated PAG oil. Containers of PAG oil exposed for an extended amount of time should be discarded.

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 the 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 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 PAG oil may be needed to obtain the amount of PAG oil required for the next steps. However, be careful no to overcharge the A/C system with PAG oil. An overcharged A/C system will result in decreased A/C system performance.

9. Add 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 the old PAG oil recovered in the oil recovery bottle during refrigerant recovery process to the high side port.
11. Install the A/C compressor to the vehicle. (Refer to "Compressor" installation procedure in the "Service" section of the "HVAC Service Manual.")

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.