Inspect the system for contamination
When repairing any A/C failure, carefully inspect all components in the system for any signs of foreign material or contamination. These may include metal chips, contaminated lubricant or chemical residue found in any part of the system. Properly replacing the components, correctly flushing the system and installing an in-line filter will help to ensure the longevity of the repair.
Use the right lubricant oil
Failure to add the correct amount or type of lubricant oil will cause compressor failure, leaving the part unwarrantable. For vehicles with R-134a systems, use PAG oil RL488 (Delphi part no. RL10006) for H6, V5 and R4 compressors and PAG oil RL 897 (Delphi part no. RL10007) for CVC compressors. Use 525 mineral oil for vehicles with R-12 systems. Use of any other lubricant, such as ester oil, can lead to premature system failure, especially under extreme operating conditions.
For compressors with crankcase bolts, the oil must be installed through the crankcase bolt hole. All other compressors can have the oil removed from the discharge port and added through the suction port. Once the lubricant has been put into the compressor, is it important to turn the compressor shaft with the appropriate hand tool, such as the Delphi Compressor Turning Tool (CB10049), so the compressor is properly lubricated before it is installed on the vehicle. Failure to do this can also result in premature compressor failure. To further determine the correct amount, type and process for applying lubrication, consult the replacement checklist/instruction sheet located in the part’s original box.
The importance of proper evacuation
It is important to remove all moisture inside the system when replacing a compressor. This is accomplished by evacuating the system until the correct vacuum level is reached. If all moisture is not removed when the system is recharged, the moisture will react with the oil and will become acidic and corrode the inside of the system components, creating the potential for premature failure and poor performance issues.
Non-warranty issues
Typical unwarrantable situations include complete compressor kits with no evidence of installation; parts that are damaged due to rough handling and/or incorrect installation (such as broken electrical connectors or holes in the compressor case); contamination of the compressor; and severe overheating of the compressor, indicated by burnt paint or blistered/melted labeling.