Out of 6 or seven candidates we ended up with three working fine at the end of the day. Brian brought a virgin bottle of the environmental hazard, for which I am legally licensed. I also have a Freon recovery machine, which came in handy today.

We checked the function of each system, looking for problems with the protection switches and the AC controller. Then we checked that the system would hold a good vacuum. We weren't equipped to manage leaks today, unless they were loose fittings. So, any that didn't hold vacuum were put off until another day.

One of Kirk's cars with the new compressor did fine. Then we tried to do Steve's. Things seemed good as the compressor clutch engaged after fixing the controller by replacing the infamous relay. But, it was not to be, as the compressor erratically compressed.

Steve, it could be the clutch, although it appears to be engaging. You probably should go ahead and bite the bullet on a rebuilt compressor.

After that we did Rich's. Initially the clutch would not engage unless energized directly, despite jumping all the switches. So, that pointed to the infamous controller relay. Once replaced by Steve, our newly crowned AC controller relay expert, Rich's system operated as it should and charged fine.

My car was ready for a charge after replacing a bad hose. It held vacuum and took the charge like gangbusters, putting out 20F air (freeze switch temporarily bypassed). Out of nowhere, the compressor started making ugly noises, and we shut it down. Testing showed the belt oscillating strangely when the compressor engaged. This may explain why I busted a perfectly good AC belt last year. The compressor appears to be partially seizing. I thought it seized last year, but then it ran OK recently until getting a charge today. I should flush the system before installing the new compressor. Anyway, we reluctantly sucked out the charge with the recovery machine, and went on to the next car.

Next up, Loren's system also proved to have a bad relay, as only 6 volts was being delivered to the compressor clutch. Steve went at it again, and Loren eventually left the premises with 30F AC (while we had the freeze switch temporarily bypassed).

Kirk's other 928 would not completely hold vacuum, but drifted slowly down. We fussed over it a bit, but decided it needed some attention to leaks.

Thanks to Kirk for the pizza and drinks!

Kirk and Rich's cars lined up for service. My 79 covered to the left.


Brian and Gerry watching Kirk examine the heater valve. Note 30# jug of juice in lower center.


Rich and Steve "rebuilding" Rich's AC controller.


Brian watching the action. AC recovery machine (thank you eBay) to the left.


Two of the infamous relays removed and autopsied. Not the discolored arms.


Close up - look at the blued arm.


Steve cutting patch wires.


The underside of the circuit board with the relay depopulated.


Steve practicing his craft.



Rich reassembling the case.

 

Thanks for hosting Bill...

My wife was really impressed to hear about your setup and I was amazed that we got it to blow so cold...

Please PM your E-mail...

It was really nice meeting everyone...

Loren

 

Looks like it was a fun day -- I wish I could have made it out there, but I'm packing as fast as I can so I can still make SATL.... Bill, at the rate you're going, you're going to have to have the driveway widened and the garage ceiling raised before the year is out...

 

Dr. Bob. Please move to the Washgington DC area. Next week would be great!

 

Hey--

This was the Bill Ball effort in the SF Bay area. Notice the lift ramps used as adjustable-height work surface. I don't have that. That cute little rolling stool with the parts bins underneath? None of those here. AC recovery machine and a new 30# cylinder of R12? I have the freon but not the fancy recovery machine.

Bill really deserves the thanks for his relentless support of the 928 community. As many know, just a simple evacuate-and-charge, with no leak-check or repair, can easily run several $hundred. I haven't looked at the costs of those recovery machines in the used market, but new they are $thousands. Getting a feel for this? Bill is providing some really serious support for the community just on the AC systems. Count the TB parties where he's been the master chef, and the countless hours he's spent with other kinds of support for the group. My efforts don't even break through the noise filter compared with Bill's.

-------------------
The rest of the group:

I hope all you newly-cool 928 owners somehow managed to foot the bill for that cylinder of freon. I know that it's tough or impossible to get Bill to accept $$ for the support he shares, but you can easily defray some of the costs with "gifts". Gift certificates are available from Sears, Harbor Freight, etc, and will always get put to good use.

Most tool and supply donations make it a lot easier for the next guys. One of the recent timing-belt-party participants made a very generous tool donation here a month or so ago. It's not necessary, but it does make some of the projects a lot easier around here for me as well as for those who visit later. Use your imaginations as you work in someone's garage, and find something that will fill a gap for them.

 

Very well put Dr. Bob.

 

Yesterday's session was how you'd like these things to go. At one point literally everybody was working on something. I could have left, and things would have putted right along. Besides the AC, the group did front bake pads and rotors on Gerry's car. Near the end of the day a non-928 friend dropped by to get help with installing a window regulator, and Kirk and Loren pitched right in on that.

During the day it sure looked like I was running a car repair business out of my house, violating the CCNRs (no car repair in the driveway) and zoning code. It was just too much fun, however. As long as we keep the driveway activity to minor maintenance and service (no torque tube extractions), we should be OK.

Brian acquired the R12, and we are providing it at cost. The AC tools are something I acquired for myself after being disapppointed by the recommended local AC shop. I have received huge donations, including tools, from various members. Regardless, the whole thing is just a lot of fun and a great learning experience.

 

Local headline:

Bill does his part to keep local hooligans off the streets.

 

Local headline (page 6):

Alamo resident succeeds in creating World's fastest refrigerator.

 

...World's Fastest Freezer! My 89 was blowing 20F out the vents at full charge.

 

Bill,

I stand corrected.

Rob

 

Bill and I went over my system again tonight. Checked for leaks with vacuum. Seemed to hold fine, so we tried to charge it up and what do you know it decides to take the charge. So, I have good pressure in the system and it cools. I will check it when it is warmer, but it looks like we can add another success to the a/c repair day. Another big thanks goes to Bill for his continuous efforts in helping me with my shark.

 

I told Steve we needed to check our work again today as the way his system acted yesterday made no sense. It seemed the compressor was not compressing even though the clutch was operating, but I wasn't comfortable with that conclusion. We were moving pretty fast yesterday. So, tonight we just redid everything and this time the compressor worked just as it should and we got a reading of 18F at the vent before the freeze switch kicked in. It was only 64 outside. That's good enough.

So, we were 4/6 with my car being one of the failures.

 

Actually, you guys should take credit for another a/c repair yesterday, too...mine!

Following the chart Bill Ball posted, and using the tips SteveB pm'd me, I was able to replace my a/c clutch relay sucessfully.

Ed MD made the diagnosis for me at SITM, and Dr Bob's relay replacement write-up was the treatment. Someone else has an excellent test protocol on Nichol's 928 Tips page that I used to verify Ed's findings and familiarize myself with the functioning of the system.

Anyway, my thanks to the 928 community for all of its support!

 

Good job Chaadster. Glad to hear it was a fix for you as well.