AC Solution BMW E28 Sanden Conversion Kit User Manual

AC Solution BMW E28 Sanden Conversion Kit

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Welcome to the official A/C Solutions E28 Sanden Conversion Kit user guide. This document contains product specifications, installation instructions, and troubleshooting for the E28 chassis. This user guide is intended for the BMW owner with basic mechanical skills; however, the evacuation and charging of freon should be handed by a licensed A/C professional. Assembly instructions assume the vehicle is stock and still retains all its original equipment. Always conform to basic safety standards and procedures when working with automotive chemicals, tools, and electrical equipment. If you are uncertain about your mechanical abilities during the removal or installation, please consult a certified professional mechanic. If you or your mechanic has any questions regarding this kit, or would like to provide feedback, please do not hesitate to contact us at [email protected].

Disclaimers

R134a is a potent greenhouse gas with a global warming potential that is 1,430 times that of CO2. Use of HFC-134a in MVAC systems accounts for an estimated 24% of total global HFC consumption. It is the most abundant HFC in the atmosphere. HFC-134a will no longer be approved for use in new light-duty vehicles manufactured or sold in the United States as of model year 2021 as a result of EPA’s July 2015 final rule under SNAP (July 20, 2015, 80 FR 42870); however, servicing of existing vehicles using HFC-134a with HFC-134a will not be impacted and will continue to be allowed. This information is current as of April, 2022.
Prop 65 WARNING: This product can expose you to tetrafluoroethylene, which is known to the State of California to cause cancer. For more information, go to www.P65Warnings.ca.gov.
By opening this product, the user assumes all risk. Improper use or handling of automotive equipment and tools can lead to injury or death.

Components Included

• Parallel flow condenser (complete with fan brackets)
• Sanden compressor (SD5H14 6630) w/ 1-year warranty
• Low-pressure suction line (LINE A)
• High-pressure discharge line (LINE B)
• High-pressure condenser return line (LINE C)
• Sanden compressor bracket
• Compressor mounting hardware
• Condenser supporting bracket mounting hardware
• Condenser supporting brackets
• Fan mounting hardware
• R134a O-rings
• Filter drier
• V-belt
• Heat shrink tubing
• 22ga crimp
• Body edge trim
• Trim screw
• Instructions

Tools Needed for Assembly

Tools and equipment needed for removal will vary by model/year.

• Metric combo wrench set
• Metric socket set
• Combo crimp tool
• Pencil torch/lighter (for heat shrink)
• PAG oil (for O-ring installation)
• PTFE thread sealant or freon compatible sealer

Diagrams

System Check & Optional Items Needed

Depending on the condition of the vehicle, the following components should be inspected for proper functionality/leaks/damage/etc. prior to the assembly of the new system as they will all affect A/C cooling performance. Ohm values and other system specifications can be found in your workshop manual. Freon operates in a closed system and will not function properly with leaks. It is imperative that the system be flushed and decontaminated prior to installing the new components.

• A/C high-pressure switch (ensure ohm values are within range; inspect for leaks)
• High-pressure drier return line (inspect rubber hose for leaks)
• Auxiliary fan and auxiliary fan relays, switches, etc. (check for functionality)
• Expansion valve (R12 type is acceptable, but R134a type is preferred)
• Evaporator (inspect for leaks and/or damage)
• Interior A/C selector switch (check for functionality)
• Interior A/C line O-rings (inspect for leaks)
• Interior A/C blower motor (check for functionality)
• Interior temperature sensor (ensure ohm values are within range)
• Evaporator temperature sensor (check for functionality)
• Evaporator regulator/control module (check for functionality)
• Fresh air flap control unit, actuator, and potentiometer (check for functionality)

Installation Instructions

Do not discard of any of the original components as some may be used during the installation process.

PART 1 OF 2: DISASSEMBLY

Remove A/C compressor

1. Discharge and evacuate the existing freon. Once evacuated, flush the system to remove old oil and contaminants.
   NOTE
   The evacuation of freon (R12 or R134a), must be done by a certified
   A/C shop as its chemicals are toxic and harmful to the environment.
   Always perform an evacuation/discharge in a well-ventilated area.

2. Disconnect the negative ( – ) cable from the battery.

3. Remove the low-pressure suction line (LINE A).
   NOTE –
   For model with fuel coolers, you will be required to remove and cap the fuel lines as the fuel cooler will not be reused during install.

4. Remove the high-pressure discharge line (LINE B).

5. Disconnect the wiring from the wiring harness to the compressor.
   NOTE –
   Depending on the year, the vehicle may have 2 wires exiting the compressor for the external temp sensor cut off switch. Disconnect one/both from the wiring harness loom.

6. Remove the compressor V-belt and compressor.

7. Remove the compressor adjustment bracket and lower triangular bracket – leaving the aluminum accessory bracket on the engine block.

Remove filter drier

1. Disconnect/loosen the high-pressure condenser return line (LINE C) and high-pressure drier return line (LINE D) from the filter drier.
   NOTE –
   Do NOT open or install the new drier at this time.

2. Disconnect the high-pressure switch connector from the wiring harness and unbolt and remove the filter drier

3. Remove the high-pressure switch from the existing drier, but do NOT yet install on the new drier.

Remove condenser and auxiliary fan

1. Remove the aux fan/condenser plastic cover.

2. Remove the high-pressure condenser return line (LINE C) (this will not be reused).
   NOTE –
   Removal of the RH side grill and headlight is recommended for additional line access.

3. Disconnect the aux fan connector from the wiring harness.

4. While leaving the aux fan attached, remove the condenser and fan assembly from the condenser supporting brackets that are attached to the chassis/core support.

5. Remove the 4 condenser supporting brackets that are attached to the chassis/core support.
   NOTE –
   Set the 4 10mm screws aside as they will be used during install.

6. With the condenser out of the car, remove the 3 nuts that hold the fan and separate the fan from the condenser.
   NOTE –
   Set the fan hardware aside as it will be used during install.

This concludes disassembly. At this time, it is suggested to clean and degrease any areas of the chassis that are now accessible with the A/C system partially removed. Keep all your original components as some will be used during the installation process

PART 2 OF 2: ASSEMBLY

Install auxiliary fan to parallel flow condenser

1. Place the new condenser on a flat surface with a piece of cardboard over top to protect the fins.
2. Rotate and align the fan in position with the wiring and isolator block mounted to the top side of the condenser as shown:
3. Using the 3 supplied washers, assemble and tighten the fan to the condenser in the following orientation with the nut on the outside of the fan shroud as shown:

NOTE –
The fan brackets may not initially line up, but once the bolts are tightened, the fan will lock into place.

4. Auxiliary fan assembly is now complete.

Install condenser to chassis

1. Using the original 10mm trim screws used during removal, install the 2 short condenser supporting brackets (hand tight) to the driver’s side (R) of the chassis/core support in following orientation:
   NOTE –
   Install the driver’s side condenser supporting brackets with the large slot to the chassis/core support.

2. With the aux fan attached, loosely install the condenser into position with the adjuster tabs behind the condenser supporting brackets.
   NOTE –
   It may be helpful to hang and float the condenser from the hood latch while aligning the adjuster brackets.

3. With the condenser in its approximate location, install the 2 long, passenger side (L) condenser supporting brackets (hand tight) using the original 10mm trim screws. Refer
   to the orientation in the diagram above.

4. Using the 4 supplied 8mm trim screws, adjust, align, and tighten down the condenser so that it is 3-8mm from the front of the radiator on all 4 corners.

5. Once tightened to final position, connect the aux fan to the wiring harness

6. Condenser and aux fan installation is now complete.

Install compressor and mounting bracket

1. Using the supplied wiring kit, splice and crimp the original male bullet connector from the end of the old compressor to the single wire coming off the new compressor.
   NOTE –
   Depending on the year, the vehicle may have 2 wires exiting the compressor for the external temp sensor cut off switch. This can be bypassed as it will not be needed on the new compressor.

2. Apply heat shrink and check electrical connection.

3. With the old compressor adjustment bracket and accessory bracket removed, fit and install the new compressor bracket with the supplied hardware and tighten. Refer to the orientation below:

4. Install new V-belt and tighten.
   NOTE –
   For initial installation, it is recommended to tighten the V-belt before installing the AC lines to ensure they are positioned in the proper orientation. This will ensure easy removal of the V-belt in the future without damaging the lines.

5. Connect compressor wiring to the wiring harness.

6. Compressor and mounting bracket installation are now complete and ready for lines.

Install filter drier

1. Carefully open the filter drier (it will be charged with Nitrogen), and transfer over the high-pressure cut off switch (or install new). Coat with a freon compatible thread
   sealant or PTFE tape and tighten until snug.

2. Place filter drier into location leaving the mounting nut loose for ease of installing lines.

3. Connect high-pressure switch to the wiring harness.

4. The filter drier installation is now ready for lines.

Install A/C lines

1. Install the high-pressure condenser return line (LINE C) from the drier to the condenser using the supplied O-rings (1x small, 1x medium) and tighten.
   NOTE –
   O-rings must be lubricated with PAG oil when installed.

2. Refit the original high-pressure drier return line (LINE D) to the drier using the supplied O-ring (1x medium).

3. Install the high-pressure discharge line (LINE B) from the condenser to the compressor using the supplied O-rings (2x medium)
   NOTE –
   It is recommended to install the compressor side first, then snake the hose up underneath the ABS unit and around the tow hook to
   attach to the condenser.

4. Using the supplied 8mm trim screw and the original hose clamp, support the using the factory brake ducting mount underneath the ABS unit.
   NOTE –
   If you have factory brake ducting, you can reuse your original trim screw or install new.

5. Tighten the filter drier mounting nut to chassis.

6. Using the supplied edge trim, cut and install to any areas where the new rubber hoses (LINE B or C) may contact sharp edges of the chassis.

7. Install the low-pressure suction line (LINE A) from the bulkhead to the compressor using the supplied O-rings (2x large).
   NOTE –
   For M30 applications, the charge port adapter (LINE A-1) is fitted between the bulkhead line and LINE A using an additional O-ring (1x large). A slight rotation of this fitting may be required to clear the intake boot.

8. Install the aux fan/condenser plastic cover.

9. A/C line installation is now complete.

Install interior O-rings

1. Remove the glove box and small trim cover to locate and access the interior lines that route to the evaporator.

2. Using the new O-rings (1x extra-large) and (1x medium), replace the existing O-rings.
   NOTE –
   O-rings must be lubricated with PAG oil when installed.

3. Reassemble glove box and interior items.

4. Interior O-ring replacement is complete.

Vacuum test and charge

1. Do NOT add oil as the compressor already contains the proper amount of oil for the system.
   NOTE –
   If you are driving the vehicle to an A/C shop for charging and/or vacuum/pressure testing, it is recommended to disconnect the A/C compressor wire to protect the system from running without freon.

2. Pull a vacuum on the system for a minimum of 1 hour.

3. Using a gauge set or A/C machine, let the system sit for a minimum of 1 hour and ensure no pressure is lost. If pressure is lost, inspect all components for leaks, then
   diagnose, repair, and retest.

4. Refer to the following table when filling the system to capacity.
   NOTE –
   Charging and filling of the system should be completed by a licensed A/C professional. Do NOT overcharge the system as it will result in catastrophic failure.

This concludes assembly. If you or your mechanic has any questions regarding this kit, or would
like to provide feedback, please do not hesitate to contact us at [email protected].

TROUBLESHOOTING

References

• P65Warnings.ca.gov

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