The flex links had broken on my compressor clutch. I had difficulty finding a replacement clutch and in the process of looking for one I ended up talking to a service rep at Sanden. He said that if the links broke it was because the compressor was working too hard from some other fault. (Possible things were low oil, overcharge, inadequate cooling of the condensor ????) So I had ordered a rebuilt/service unit compressor, a new receiver-dryer, a new orfice tube assembly and "O" rings to "refurbish" my AC system. (All from my friendly Volvo parts guy for a total of about $422.)

I had intended to race my sailboat this past weekend but I had strep throat last Wed. thru Fri. So on Saturday morning I decided to undertake the less strenuous task of fixing the AC system. I had three "problems".

1) Thanks to the efforts of the EPA it is EXTREMELY DIFFICULT to find a vacuum pump to rent for AC work. All work is supposed to be done using a recovery system in order to prevent R12 from getting released. (I guess all automotive AC work is surposed to assume there might be some R12 in the system. I was told there is a $10,000 fine for releasing any R12 on purpose.) I did find a suitable one for $28 a day but I had to make my own adapter to hitch it up to my new R143a gauges. (I'm giving serious thought to buying one of the JC Whitney units for $350 to have for the next time.

2) The top rear bolt on the compressor is a s@# of a #@%$h! In order to get at it I ended up taking the alternator, air-filter and AMM assy out. I also had to remove the piping before I could get closer to it. Then using my bench grinder, I ground down the side and half of the handle on my 14mm wrench in order to get on the bolt head and be able to turn it. (One of those curved "starter" wrenches might work if the wall is thin.)

3) There was confusion in my mind regarding the instructions for how to deal with the oil in putting in the replacement parts. (I have the Volvo manual set and was using it to guide me through the process.) I now think my system was extremely low on oil and that may have been the reason for the whole problem. No oil was in the old receiver/dryer at all. I only drained 100 ml out of the old Sanden compressor. The new/replacement unit was a Zexel with a label indicating it had, (or needed to have added?), 200ml of Volvo oil already in it. I drained about 50 ml out of the new unit and it was still comming rapidly so I assumed it had the 200 ml in it. I replaced the 50 ml in the compressor with new PAG oil. I also put 50 ml in the new receiver/dryer when I put it in.

After sucking it down for about 2 hours I put in about 32 oz, (manual says 900 gms) of R134a and it seems to be working better than ever! Total time including messing with the bolt for about an extra hour was about 8 hours. (Next time would be about 4 hours now that I'm "experienced".)