I spent a couple of hours yesterday mounting the new compressor, a Sanden SD709, and installing a new belt. The longest M8x1.25 bolts I could find at Napa were 3 1/2" yet, even with washers under the heads, they still had 3/8" of thread left to grab with. I was satisfied with that and tightened them up good. I realized then that the flange at the condenser is aluminum and therefore couldn't braze it as I had planned. That being the case, a friend of mine in the a/c business took them to work with him today and had someone weld, braze and crimp the fittings to the hoses.

Today, with the compressor mounted, I mocked up the lines and fittings to verify the lengths of #8 and #10 barrier hose needed. The compressor was shipped with 5oz. of the recommended PAG100 oil. I added an additional ounce to make an even 6oz. The formula, IIRC, is 3.25oz for every pound of refrigerant. I also added some dye at this point before plugging the fill port.

Here is the #10, low pressure side, hose from the compressor to the expansion block/valve. I also bought a new drier in order for the compressor's warranty to be honored.





Now, the #8, high pressure side, from the compressor to the condenser.



Once everything was sealed up, we vacuumed the system for 15-20 minutes to remove any moisture that may have accumulated, let it sit for 5 additional minutes and verified that it held. Switched the machine to charging mode and charged the system to 2lbs of R-134a. I started the truck and let it idle for a few seconds. I pushed the a/c button on the controls and instantly heard the "click" of the compressor clutch. I allowed it to continue idling while we checked for leaks with soapy water. I was glad to see no bubbles coming from any of the sealing points and fittings! It cools down very well but, of course, the blower motor needs a relay wired to it as Jim Lane recommended to us all. I might just go ahead and replace the motor when that time comes. Afterall, it's 20 years old.

I know of a couple others doing this retrofit as well. If anyone else has any questions, feel free to ask. I won't hesitate to answer and answer to the best of my memory and knowledge.

 

I did switch over last night.

I used the stock lines from the I/C truck and A/C condenser. Haven't had a chance the get R134a in it yet.

 

What did you use for a belt? I tried to use the belt that came off the parts truck (1993), but it was to long. The tensioner rubbed on the belt coming down from the alternator. I put the original belt on and it was a little bit better.