R-12 to R-134A Refrigerant Retrofit

R-12 to R-134A Refrigerant Retrofit

If you drive an older vehicle (pre-1994), the air conditioning system contains R-12 refrigerant (Freon). As long as the A/C system has no leaks and it cooling normally, there is no need to convert from R-12 to the new "ozone safe" R-134a refrigerant. But if your A/C system has lost it's charge because of a leak, collision damage, or the need to open it to replace a compressor, hose or other component, you may have to convert from R-12 to R-134a when you recharge the system

Why? Because R-12 is no longer produced in the U.S. Supplies of recycled R-12 still exist, and some R-12 is still brought in from offshore suppliers. But it is hard to find and expensive. That's why many people simply recharge their older R-12 air conditioning system with R-134a after repairs have been made.

R-134a Retrofit Conversion Costs

Does it make economic sense to retrofit an older vehicle to R-134a if the A/C system has lost its refrigerant charge or needs major repairs? The older a vehicle gets, the more it depreciates. By the time it is 15 or more years old, it may only be worth a few hundred dollars. Many owners will not put any more money into an older vehicle unless the repairs are absolutely necessary to keep it running. Even then, it may be less expensive to get rid of the vehicle or to junk it than to fix it up. Even so, A/C is something that's hard to do without especially during hot weather. Hot summer temperatures and high humidity can make driving in city traffic unbearable.

A professional retrofit by a repair shop can cost hundreds of dollars, depending on what they do. But on many older vehicles, you can save money and do the job yourself - if you have some know-how and the right equipment.

WHEN R-134A RETROFIT MAKES SENSE

There is NO reason to retrofit a vehicle to R-134a as long as the R-12 system is cooling properly and contains a normal charge of refrigerant. A/C systems designed to use R-12 will cool best when charged with R-12 refrigerant. Even if the system leaks, repairing the leaks and recharging it with R-12 is usually the best repair alternative. Converting to R-134a typically reduces cooling performance somewhat, and may require some additional modifications depending on the vehicle model year.

Where retrofit makes the most economic sense is when an A/C system requires major repairs such as a new compressor, condenser or evaporator.

The average repair bill to retrofit when other A/C repairs are needed, according to the Mobile Air Conditioning Society (MACS), is about $100 over and above any other repairs that may be needed (such as replacing the compressor, condenser or evaporator, etc.). The cost to retrofit usually does not add that much to the total repair bill because converting 1990s vintage vehicles to R-134a in most cases is fairly easy and does not require many (if any) changes. If the vehicle has barrier style hoses and the compressor and seals are compatible with R-134a, the only thing that has to be changed is the compressor lubricant.

TWO WAYS TO DO A R-134A RETROFIT

A retrofit can be done one of two ways. The first is to follow the vehicle manufacturer recommended retrofit procedure. This generally involves removing all the old mineral oil from the system, replacing the accumulator or receiver/dryer with one that contains X-7 desiccant, replacing O-rings (if required), installing or replacing a high pressure cutout switch (which many shops seem to forget), changing the orifice tube or expansion valve (if required), then adding the specified PAG oil and recharging the system with R-134a. On some applications, installing a more efficient condenser may be recommended for improved cooling performance. After the modifications are made, the system is recharged to about 85 to 90% of its original capacity with R-134a.

Federal law also requires the permanent installation of R-134a fittings on the high and low service ports to reduce the chance of refrigerant cross-contamination the next time the vehicle is serviced. Labels must also be installed to identify the system has been converted to R-134a.

Installing service fitting adapters allows R-134a to be put into a R-12 system.

The other approach to retrofit is the "quick and cheap" one. On many 1989 through 1993 vintage vehicles, R-12 A/C systems can be converted by simply recovering any refrigerant that is still in the system, adding POE oil (which is compatible with both types of refrigerant), and recharging to 85 to 90% capacity with R-134a.

A simple retrofit may therefore cost no more than a few cans of refrigerant and some compressor oil -- provided there's nothing else wrong with the A/C system. But simple low cost retrofits may not give the best cooling performance, and may not even be possible on some vehicles. Any compressor that has Viton seals is not a candidate for retrofit. This includes original equipment compressors such as Tecumseh HR980, some Keihin compressors and some Panasonic rotary valve style compressors on older Japanese cars. On these, the compressor must be replaced.

Compressor durability is also a concern with some vehicles. Because R-134a raises compressor discharge pressures and increases the compressors work load, some lightweight compressors may not be rugged enough to tolerate R-134a over the long haul. This applies to the Harrison DA6 and Ford FX-15 compressors. The Harrison DA6 can be replaced with a HD-6, HR-6 or HR-6HE compressor. The Ford FX-15 compressor can be replaced with a FS-10 compressor.

Regardless of which retrofit method is used, cooling performance will vary depending on the design of the system. As a rule, expect anywhere from a 3% to 15% decrease in cooling performance when an R-12 system is converted to R-134a. Systems with relatively large or efficient condensers will experience less of a drop in cooling performance with R-134a than those with smaller or less efficient condensers.

ADDITIONAL R-134A RETROFIT TIPS

One way to improve cooling performance when retrofitting an older R-12 system to R-134a is to install a "variable valve" orifice tube in place of the standard fixed orifice tube. These aftermarket variable orifice tubes allow the flow rate through the valve to change for better cooling at idle and low speeds. Such a valve can lower the A/C outlet air temperature by as much as 5 to 8 degrees, which can make quite a difference if the vehicle is crawling along in stop-and-go city traffic.

Adding an extra cooling fan can help boost cooling performance, especially at idle and low speeds. Many older rear-wheel drive cars and trucks do not have a separate electric fan for the A/C condenser. They rely solely on the belt-driven fan for cooling, which may not be adequate in extremely hot weather with R-134a. Installing an auxiliary fan that comes on when the A/C is turned on give provide the extra airflow needed to carry away the heat.

Installing a larger or more efficient condenser can also help compensate for losses in cooling efficiency with R-134a. If the original condenser or evaporator is being replaced because of a leak, damage or defect, make sure the replacement unit has the same or better BTU rating. Some aftermarket replacement condensers and evaporators may not deliver the same cooling performance, and create a problem you did not have before.

When a compressor fails, it can throw metallic debris into the system. Most of the junk ends up in the bottom of the condenser, but some of it can also be blown back into the suction hose. Flushing the condenser, hoses and evaporator with refrigerant or an approved solvent may remove most of the debris, but parallel flow condensers cannot be flushed effectively. Replacement is often recommended if debris is found in the system. Most experts also recommend installing an in-line filter (high side and/or low side) to protect the replacement compressor and orifice tube or expansion valve. There are also filter screens that can be installed in the suction line to prevent any debris from reentering the compressor, too.

ALTERNATIVE REFRIGERANTS

The vehicle manufacturers still do not approve of any alternative refrigerants other than R-134a for retrofit, though a variety of alternative refrigerants currently meet the EPA SNAP (Significant New Alternatives Policy) rules for environmental acceptance. Most of these are blends that are formulated to replace R-12 in older vehicles.

It is important to remember that R-134a or any other alternative refrigerant cannot be mixed with R-12 or used to top off an R-12 system. If an A/C system still contains any R-12 at all, it must be removed using approved recovery equipment (venting is not allowed) before a new refrigerant is added to the system. This is an absolute must to prevent cross-contamination of refrigerants and cooling performance problems.

Mixing different refrigerants can cause big problems. For one, it will increase the system operating pressure. This can result in a loss of cooling performance and may overtax the compressor to the point where it fails. R-134a and mineral oil will not mix. So if somebody recharges an R-12 system with R-134a and does not add a compatible lubricant, the compressor will soon fail.

• 57% had R-12 and R-134a mixed together (up 10% over last year).
• 20% had R-22 in R-12 systems.
• 20% had two or more refrigerants mixed together (down 10% over last year).
• 30% contained hydrocarbons (propane or other flammable hydrocarbons).
• 2% had too much air.

The same survey also revealed that only one out of 10 technicians knew about EPA SNAP rules, the Significant New Alternatives Policy regulations that prohibit refrigerant venting, require recovery and recycling, prohibit the intermixing of different refrigerants or the use of flammable refrigerants.

Two out of five technicians also did not know the service fittings on an A/C system MUST be changed if the system is converted from R-12 to R-134a or anything else. And three out of five technicians did not know mixing R-12 and R-134a could cause problems.

For more information about the usage of Alternative Refrigerants, see Alternative Refrigerant Report

Click Here for info about A/C R-134a Retrofit Guide 

 More Air Conditioning Articles:

A/C Cooling Problem: Blows Warm Air Only No Cool Air

Troubleshooting Air Conditioning Problems

Troubleshoot Automatic Climate Control System

Troubleshooting A/C Cooling Problems with Temperature

How To Recharge Your Car's Air Conditioner

Refrigerant Contamination 

Alternative Refrigerants

New Automotive Refrigerants 

Flammable Refrigerants

California proposes ban on R-134a sales to motorists

MACS Recommended A/C Service Procedures (PDF file - requires Adobe Acrobat Reader to view).

A/C Compressor Failures

A/C Condenser Flushing


 Click Here to See More Carley Automotive Technical Articles

New Automotive Refrigerants

New Automotive Refrigerants For Your Vehicle

What the future holds for automotive refrigerants is uncertain, but changes are happening and more changes are coming. R-134a refrigerant contineus to be used in many late model vehicles, but many new cars are now being equipped with A/C systems that use R-1234yf refrigerant. Other refrigerants may also be coming as R-134 is gradually phased out in the years ahead.

The Europeans want to phase out R-134a in all new vehicles by 2017. The European rules require any new refrigerants must have a global warming potential of less than 150. The U.S. EPA also wants car makers to switch to a different refrigerant to lower the overall carbon emissions of the vehicle fleet. Carbon credits will be given to auto makers who make the switch to a refrigerant that has a lower Global Warming Potential (GWP).

Though R-134a poses no danger to the ozone layer if it escapes into the atmosphere, it is a "greenhouse gas" with a fairly high global warming potential of 1300 (compared to 1 for carbon dioxide, which is nature's own greenhouse gas). A leak that allows only an ounce or two of R-134a to escape into the atmosphere may not seem like a big deal, but over time it all adds up, especially when you multiply small leaks times the hundreds of millions of vehicles that now share planet Earth with humanity.

According to November 2006 report by the Energy Information Administration, vehicles in the U.S. leaked 50.8 thousand tons of R-134a into the atmosphere, equivalent to to over 66 million tons of greenhouse gases. The emissions are 7% higher than in 2004, and up 273 percent since 1995.

North American auto markers have started to replace R-134a with R-1234yf. Auto makers are also redesigning their A/C systems following goals in mind:

* To use less refrigerant. Some newer A/C systems now use only 12 to 14 oz. of refrigerant, which is much less than the 24 to 60 oz. charges that most older A/C systems use. As time goes on, we will see more and more of these low capacity A/C systems in new vehicles.

* To reduce refrigerant leakage 50% over the life of the vehicle. This requires using improved seal designs, hoses and o-ring connections.

* To improve cooling efficiency 30% with more efficient condensers, compressors and operating strategies (things like variable displacement compressors that run all the time rather than cycle on and off). Mercedes has this now.

* To reduce the cooling requirements inside the passenger compartment 30% by using reflective coatings on glass, heat reflective paint, and venting the interior during hot weather.

Changes are also being made to reduce refrigerant losses when the A/C system on a vehicle is serviced. The latest generation of refrigerant recovery machines do a better job of removing all of the refrigerant from the system. Older machines can leave as much as 20 to 30 percent of the old refrigerant charge in the system. The residual refrigerant can escape into the atmosphere when the A/C system is opened to replace parts. Some of the newest machines can pull up to 95% of the refrigerant out of the system to reduce the amount of R-134a that escapes into the atmosphere.

Auto makers have also been adding leak detection dye to the refrigerant to make it easier for technicians to detect refrigerant leaks. A leak will leave a telltale stain that glows greenish-yellow or greenish-blue when illuminated with an UV light source. Leaks as small as 1/8 oz. of refrigerant per year can be detected this way.

The Europeans auto makers are taking a different approach. They want future A/C systems to be as environmentally benign as possible. That means no chlorine-containing CFCs such as R-12 or R-22 that cause ozone depletion, an no refrigerants that could add to the global warming problem (which includes R-134a). Any new refrigerants must also be nontoxic and safe, though that doesn't necessarily mean nonflammable.

For more information, see Flammable Refrigerants

In an effort to address these issues, the Alliance for Responsible Atmospheric Policy (ARAP) and the U.S. Environmental Protection Agency (EPA) have held a series of annual meetings to discuss and evaluate alternatives to R-134a. The first of these meetings was held in 2003 by the European Commission in Brussels. As a result of that meeting, the European Commission decided to allow carbon dioxide, HFC-152a and other refrigerants as possible replacements for R-134a.

CO2 as an Alternative Refrigerant

When used as a refrigerant, CO2 (called R-744) requires extremely high operating pressures (up to 1,800 psi on the high side, and 350 to 400 psi on the low side), compared to 300 to 400 psi on the high side for R-134a. The reason the pressures are so high is because CO2 does not condense in the refrigeration circuit. It remains in the gaseous state. Consequently, the front heat exchanger is called a "cooler" rather than a condenser.

CO2's main attribute is that it has virtually no impact on global warming or ozone depletion. CO2 is also nontoxic in small doses but concentrations over 5% can be lethal. It is also cheap (about $10 for a 20-lb. cylinder) and nonflammable. Numerous test vehicles with CO2 A/C systems have shown that CO2 does provide cooling performance comparable to R-134a.

SAE has developed service fitting standards for R-744. Leak detection presents a challenge because natural levels of CO2 in the atmosphere may be higher than the amount emitted by a leak from an A/C system. Some type of ultrasound or infrared equipment may be required to find R-744 leaks, but dyes may also work or plain old soap bubbles.

HFC-152a

HFC-152a is almost a straight drop-in substitute for R-134a. The molecule is similar to R-134a except that two hydrogen atoms are substituted for two fluorine atoms. It has similar operating characteristics to R-134a but cools even better. One test in an otherwise unmodified Saturn Ion found that A/C duct outlet temperatures were several degrees C lower with HFC-152a. Fuel efficiency was also up 10% at idle, and 20% at highway speeds. The system typically requires only about two-thirds of the normal charge with HFC-152a and can be used with current desiccants.

An environmental benefit of HFC-152a is that it has a global warming rating of 120, which is 10 times less than R-134a, but still a lot higher than CO2. That is why HFC-152a is currently used in many aerosol products as a propellant. Its main drawback is that it is slightly flammable (Class 2A), but it is not as flammable as propane or most other hydrocarbon-based refrigerants.

The first mobile A/C system to use HFC-152a was unveiled at the Mobile Air Conditioning Society (MACS) Worldwide tradeshow in January 2004; a self-contained unit for off-road construction equipment that featured an oil-driven compressor. Made by Red Dot, the unit was a forerunner of future HFC-152a A/C systems to come.

Red Dot staff explained that the HFC-152a refrigerant used in the self-contained unit improves cooling capacity, decreases fuel use and helps protect the climate. The new technology also satisfies stringent new regulations proposed by the European Commission. Red Dot staff also said that the HFC-152a system uses new technology that will use hydraulic-driven compressors and secondary loop technology to increase reliability, safety and reduce the amount of refrigerant required.

R-1234yf

The refrigerant that may eventually replace R-134a is R-1234yf (also called HFO-1234yf). Developed jointly by Honeywell and DuPont, it is being promoted as a drop-in replacement for R-134a in both new vehicles and older vehicles, should that become necessary in the future. R-1234yf has thermal characteristics that are very similar to R-134a, so no major modifications to the A/C system are necessary. Better yet, R-1234yf has a global warming potential of only 4, compared to 1200 for R-134a, allowing it to meet the European requirements for a GWP of less than 150. Existing refrigerant leak detectors can also detect R-1234yf if it leaks. But R-1234yf is mildly flammable (though less so than HFC-152a), and the industry is still debating its potential safety.

Currently, there are NO plans to make R-1234yf directly available to consumers or do-it-yourselfers (meaning you can't recharge your A/C system yourself if your vehicle has an R-1234yf A/C system). Also, repair shops can only buy the new refrigerant in 10-pound containers, limiting the amount they can keep on hand for service work.

In early 2013, production of the new refrigerant began for a limited number of OEM applications. Production has ramped up as more and more new vehicles with R-1234yf A/C systems are introduced.

Click Here for detailed information about R-1234yf by Honeywell.

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Update: November 2008

SAE Says HFO-1234yf is Best Alternative Refrigerant for R-134a

In a recent press release, the Society of Automotive Engineers (SAE) International Cooperative Research Program (CRP) says HFO-1234yf offers "superior environmental performance" for future mobile air conditioning systems that may be redesigned for alternative refrigerants.

The CRP1234-1 and CRP1234-2 programs, launched in 2007, have investigated the safety and performance of the new refrigerant HFO-1234yf. Under the direction of the SAE CRP members (who are international experts in this field from OEMs, Tier 1 and 2 Suppliers and independent test facilities), air conditioning system performance, material compatibility and relative risks of HFO-1234yf were evaluated. Based on these studies, HFO-1234yf was judged to have the lowest risk for use in mobile A/C systems compared to all of the other alternative refrigerants that are currently being evaluated. This is based on the Life Cycle Climate Protection analysis that estimates CO2 Equivalent emissions from automotive A/C usage (as described in SAE J2766).

Click Here to view the SAE CRP1234 report on HFO-1234yf.

The study was conducted in response to European Union regulations that will require all new vehicles made for model year 2011 and later to use a refrigerant with a Global Warming Potential (GWP) below 150. Current automotive A/C systems all use R-134a, which has a GWP of 1,430. HFO-1234yf has a GWP of only four.

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Update: October 15, 2009

EPA to Approve HFO-1234yf Refrigerant for Significant New Alternatives Policy (SNAP) program

On Tuesday, October 13, 2009, EPA's Administrator signed a rule proposal that says HFO-1234yf is an acceptable substitute for CFC-12 in motor vehicle air conditioning, subject to use conditions. You can view the proposed rule on EPA's SNAP website athttp://www.epa.gov/ozone/snap/.

The public comment period on this proposed rule is for 60 days, beginning when it is published in the Federal Register early next week. Once the rule is published, you will be able to find information and to send EPA comments on the proposed rule athttp://www.regulations.gov/ , docket EPA-HQ-OAR-2008-0664. The Federal Register version of the proposed rule will be posted by the end of the week of October 19 at http://www.epa.gov/ozone/snap/regulations.html (Rule 16 on HFO-1234yf).

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Update: September, 2010

GM to Use R-1234yf Refrigerant in some 2013 Models

GM says that starting in 2013, it will begin using HFO-1234yf refrigerant instead of R134a in the air conditioning systems in some Cadillac models (XTS luxury sedan and ATS sports sedan). This will help GM meet the new greenhouse gas emission rules. The Chevy Volt plug-in hybrid electric, however, will have an R134a air conditioning system (for now).

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Update: October 21, 2010

SAE Releases 20 New Standards for R-1234yf Refrigerant

The Society of Automotive Engineers (SAE) has announced 20 new standards covering service procedures, service equipment and vehicle components for the new R-12354yf refrigerant. The standards require auto repair shops to buy all new equipment to service the A/C systems on new vehicles that are equipped with HFO-1234yf. The new equipment requirements are covered in J2911, which includes a provision that the recharging machine must test the A/C system for leaks. If a leak is found, the machine will not recharge the vehicle until the leak is fixed. J2843 covers recovery procedures.

J2845 will require technicians who work on R-1234yf systems to be certified in service and recovery procedures.

There is also a new standard J2842 that prohibits shops from repairing leaky evaporators, or fixing a vehicle with a used evaporator from a salvage vehicle because of possible safety risks. R-1234yf is mildly flammable, so the reason for replacing a leaky evaporator with a new one is to minimize the risk of a repeat leak that might allow the refrigerant to enter the passenger compartment.

Currently, there is no mandate in the U.S. to phase-in R-1234yf by a certain date, so the phase in will be gradual and will likely be spread across many model years as new vehicle models are introduced. This will likely create a LOT of confusion in the years ahead as to which type of refrigerant to use in a particular model year vehicle. R134a or other refrigerants must NOT be intermixed with or substituted for R-12354yf in new vehicles if service is required as damage may result to the A/C system due to different operating pressures.

New vehicles with R-1234yf A/C systems also require a unique type of PAG compressor oil. Compressors for these systems have been redesigned to keep more of the oil in the compressor to improve cooling efficiency. Larger, more efficient condensers are also required because R-1234yf cools about 10 percent less efficiently than R134a.

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Update: September 4, 2012

MACS Announces R-1234yf Technician Training Program

The Mobile Air Conditioning Society (MACS) now has a new training program to certify automotive technicians to SAE J2845 under the SAE J2911 program for the upcoming introduction of R-1234yf refrigerants in new vehicles.

SAE International created the J2911 and J2845 standards in response to changes in the refrigerants that will be used in mobile A/C systems. The SAE J2845 standard covers servicing of R-1234yf and R-744 mobile air conditioning (MAC) systems. The training teaches technicians how to identify which refrigerant is in a vehicle, how to handle it safely, and what type of service information, tools and equipment are needed to service the vehicle.

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Update: November 2012

Mercedes, BMW and VW say they will NOT use R-1234yf Refrigerant because of Safety Concerns

Citing concerns that the alternative refrigerant R-1234yf can burn in real life conditions inside a vehicle (per lab simulation test results), Mercedes, BMW and Volkswagen said they will NOT switch their vehicles to R-1234yf. At this time, it appears that CO2 may be the best alternative to R-134a, according to the German auto makers.

R-1234yf can by ignited by a spark within seconds of its release, and emits highly toxic fumes and acids as it burns according to tests conducted by Daimler. CO2 is nonflammable and is carbon neutral, so it appears for now that R-1234yf is on hold as far as two of the leading German auto makers are concerned.

On a related note, Cadillac has temporarily suspended installing R-1234yf in the ATS sports sedan and XTS luxury sedan. For now, these vehicles will be produced with R-134a pending further investigation into the potential flammability issues with R-1234yf.

Note: See June 26, 2013 update below for more information on this subject.

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Update: April 13, 2013

Latest Alternative Refrigerant May be a Blend Called AC-6

To counter the virtual monopoly that Honeywell and DuPont have on the production of R-1234yf refrigerant (which is currently selling to car dealers for around $60 to $70 a pound!), Mexichem has developed a blended refrigerant that could sell for as little as $10 a pound, and would work in any R-134a A/C system. The AC-6 blend contains 85 percent R-1234ze, 9 percent R-134a and 6 percent CO2. The Global Warming Potential (GWP) of the new blend is 6.0, which is well under the GPW requirement of 150.

For AC-6 to be approved, the auto makers would have to do extensive testing, and the EPA would have to add it to its approved alternative refrigerant list.

The main drawback of a blended refrigerant is that some of the ingredients in the mix tend to leak out of an A/C system faster than others, effectively changing the blend over time and its thermal characteristics. Currently, there is no aftermarket A/C service equipment that can reconstitute a blended refrigerant. If an A/C system charged with AC-6 required service, the old refrigerant would have to be recovered from the system and replaced with new refrigerant rather than recycled.

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Update: June 26, 2013

SAE now says R-1234yf is Safe for Use in Passenger Car A/C Systems

After extensive testing and review, SAE International has concluded that Honeywell's new R-1234yf low-global-warming-potential mobile air conditioning refrigerant is safe for use in automobiles. Yes, it can be flammable under certain conditions, but those conditions are highly unlikely to occur in a real world crash, concludes SAE.

To read the official press release, Click Here.

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Update: April 2014

R-1234yf A/C Systems Now in Production

The first U.S. vehicle to use R-1234yf refrigerant was the 2013 Cadillac XTS. Cadillac also tried R-1234yf in the Cadillac ATS, but stopped only one month into production because of A/C compressor noise and vibration issues. Early production ATS models were recalled and retrofitted back to R-134a (which apparently works fine in an A/C system designed for R-1234yf).

For model year 2014, R-1234yf is used in the Jeep Cherokee, Chrysler 300, Dodge Ram 1500, and Dodge Charger, Challenger and Dart. It will also be used in the 2015 Chrysler 200.

Most auto makers are expected to have numerous R-1234yf applications by model year 2017 and beyond. Auto makers receive fuel economy credits for vehicles that are converted to R-1234yf, which helps them achieve the new higher Corporate Average Fuel Economy (CAFE) requirements.

More Refrigerant Articles:

R-1234yf

Alternative Refrigerants for R-12

Flammable Refrigerants

California proposes ban on R134a sales to motorists

Information about Retrofitting older vehicles with R-12 A/C systems to R-134a

Troubleshooting Air Conditioning Problems

How To Recharge Your Car's Air Conditioner

Refrigerant Contamination 

 Click Here to See More Carley Automotive Technical Articles

Refrigerant Resources:

Alliance for Responsible Atmospheric Policy (ARAP)

DuPont Refrigerants

EPA FAQs on Alternative Refrigerants

Fluorocarbons.org

Flammable Refrigerants

Flammable Refrigerants To Be Taken Care Of 

Flammable refrigerants are illegal to use in an automotive air conditioning system. There are some exceptions, such as the new R1234yf refrigerant, which is mildly flammable but only under certain conditions. Flammable refrigerants may also be used in the trailer refrigeration units on heavy duty trucks. But other than these, no flammable refrigerant should ever be used in a car or light truck A/C system.

Flammable Refrigerant Fire Hazards

Propane, butane and a number of other hydrocarbon mixtures and blends actually work quite well as refrigerants, with cooling characteristics similar to R-12, R-22 and R-134a. But if the evaporator inside the passenger compartment develops a leak, the flammable vapor may create a potential for a fire or explosion. Do you really want to risk being cremated while driving your vehicle?

Another thought to keep in mind is what happens if your vehicle is involved in an accident. The A/C condenser sits right in front of the radiator and contains high pressure refrigerant vapor and liquid. If the condenser is ruptured in a frontal collision (which it often is), high pressure flammable vapor will be released, almost guaranteeing an underhood fire!

Do you really want to risk your life or the lives of your passengers by using a cheap flammable refrigerant in your vehicle's air conditioning system? R-134a is the only refrigerant that should be used when recharging a late model automotive A/C system.

EPA SNAP Rules on Flammable Refrigerants

The US EPA SNAP regulations do NOT allow the use of flammable refrigerants in vehicles.

The only exception is a new refrigerant called HFO-1234yf which is only mildly flammable under certain conditions. For info on EPA SNAP regulations, see this link:

EPA SNAP Rules Regarding Flammable Refrigerants

The Mobile Air Conditioning Society (MACS) also does NOT approve of using flammable refrigerants. Nor does the Society of Automotive Engineers (SAE). Like the EPA SNAP rules, the only exception is the new HFO-1234yf refrigerant that will start appearing in some new cars in 2013 or beyond as a replacement for R-134a.

Use R-134a Only

The EPA, MACS and SAE all say that the only acceptable replacement refrigerant for newer R-134a system is R-134a. Nothing else should be used to avoid cross-contamination problems and cooling performance issues. Older vehicles with R-12 can be retrofitted with R-134a or other approved alternative refrigerants (which also must NOT be flammable).

Here is document that contains a lot of good information about alternative refrigerants, though it is dated 1999. The basic information is unchanged, and the only update would be the approval of HFO-1234YF for future A/C systems.

Flammable Refrigerants are Against the Law!

Many city municipalities and states have laws prohibiting the use of flammable refrigerants in vehicles.

In Europe, propane is allowed in some home refrigerators, but the amount is so small that it poses no explosion or fire hazard. Refrigerators must also pass safety tests that show any refrigerant leak cannot create a fire or explosion hazard.

Flammable Refrigerants: OZ-12 and HC-12A

Alternative refrigerants that do not meet the EPA's criteria for environmental acceptability or safety include OZ-12, HC-12a, R-176 and R-405a. Flammable refrigerants such as OZ-12 and HC-12a contain large quantities of hydrocarbons (propane, butane, isobutane, etc.) and have been declared illegal for use in mobile A/C applications but are still finding their way into A/C systems because of their cheap price.

The EPA does not approve of flammable refrigerants because the EPA says they pose a significant danger to a vehicle's occupants should a leak occur. The EPA says a spark from a cigarette or a switch could ignite leaking refrigerant causing an explosion and fire.

Counterpoint: The makers of HC-12a contend that the flammability danger is highly exaggerated and there is "no evidence" to support claims that a cigarette or spark can ignite their product. They also contend that the EPA's position on their product is unfair, and that HC-12a has been successfully used in many vehicle A/C systems worldwide with no accidents or injuries due to ignition.

HFC-152a

Another alternative refrigerant that has been proposed for automotive use is HFC-152a. It has a GWP rating of 140, which meets the European requirements for combating global warming. HFC-152a has cooling characteristics very close to that of R-134a, and could probably be used as a direct substitute for R-134a with few if any modifications. But HFC-152a is flammable, so it is currently illegal to use.

One possible solution to the flammability issue HFC-152a (or other flammable refrigerants) is to add a leak sensor inside the vehicle that warns the passengers if a leak occurs, and automatically opens the power windows to vent the vapors (thus, reducing the fire/explosion risk).

Another solution is to redesign the A/C system so that it uses a "secondary loop" to keep the flammable refrigerant in the engine compartment and out of the passenger compartment. With this approach, the refrigerant circulates through an intermediate heat exchanger and chills a liquid (probably a water/antifreeze mixture) that then flows through the HVAC unit inside the vehicle. A recent report from the U.S. EPA says this approach meets its safety criteria, while also being energy efficient. But it does not reduce the risk of fire in a frontal collision, and it still poses a risk to technicians and do-it-yourselfers while recharging or servicing the A/C system.

HFO-1234YF

The newest alternative refrigerant is HFO-1234yf. The refrigerant replaced R-134a in model year 2014 on a few vehicles. It has thermal characteristics that are similar to R-134a, so only minor modifications to the A/C system are necessary (larger condenser and different PAG oil). It has a low GWP rating of only 4, which meets the European requirements for reducing global warming. But it is mildly flammable (though much less so than HFC-152a) and will only burn under certain conditions which should NOT occur in normal automotive usage.

For more information about HFO-1234YF, see 1234facts.com.

---

Update: November 2012

Volkswagen says it will NOT use HFO-1234yf Refrigerant because of Safety Concerns

Citing concerns that the alternative refrigerant HFO-1234yf can burn in real life conditions inside a vehicle, Volkswagen said that it will NOT switch its vehicles to HFO-1234yf. At this time, it appears that CO2 is the best alternative to R-134a, according to VW. This decision follows a similar announcement late last month by Daimler (Mercedes Benz) to abandon work on HFO-1234yf in favor of CO2 or other alternative refrigerants.

HFO-1234yf can by ignited by a spark within seconds of its release, and emits highly toxic fumes and acids as it burns according to tests conducted by Daimler. CO2 is nonflammable and is carbon neutral, so it appears for now that HFO-1234yf is on hold as far as two of the leading German auto makers are concerned.

---

Update: June 26, 2013

SAE says HFO-1234yf is Safe for Use in Passenger Car A/C Systems

After extensive testing and review, SAE International has concluded that Honeywell's new HFO-1234yf low-global-warming-potential mobile air conditioning refrigerant is safe for use in automobiles. Yes, it can be flammable under certain conditions, but those conditions are highly unlikely to occur in a real world crash, concludes SAE.

To read the official press release, Click Here.

Air Conditioning Related Articles:

Alternative Refrigerants

R-1234yf

New Automotive Refrigerants 

How to Recharge Your Car's Air Conditioner

Air Conditioning Inspection Checklist

A/C Cooling Problem: Blows Warm Air Only No Cool Air

Troubleshooting Air Conditioning

Air Conditioning Service Best Practices (Procedures a repair shop should follow when servicing your A/C system)

MACS Recommended A/C Service Procedures (for professional technicians) (pdf file) 

Update on R134a Retrofit 

R134a Retrofit Guide

R-1234yf Refrigerant

R-1234yf Refrigerant For Your Car

Auto makers are slowly moving toward a new refrigerant for automotive air conditioning systems. The new refrigerant is R-1234yf (HFO-1234yf), and it will be phased in slowly over time starting with some 2014 model year vehicles.

R-1234yf has cooling properties that are similar to R-134a, which has been used as an automotive refrigerant since it was introduced back in 1994 to 1995 to replace R-12. R-134a contains no CFCs, which are harmful to the Earth’s protective ozone layer, but it does retain heat well and has a relatively high Global Warming Potential (GWP) rating of 1410.

IMPACT ON GLOBAL WARMING

Automotive refrigerants that leak out of A/C systems contribute very little to the overall global warming problem, only about 0.14% according to scientific estimates. Even so, when you multiply the millions of vehicles that are AC-equipped times even a small amount of refrigerant leakage over time, the numbers can add up. Some would argue that switching to a new refrigerant is unnecessary and will hardly make a dent in climate change. Others argue that it is all a conspiracy by DuPont and Honeywell to monopolize the world automotive refrigerant market by getting regulators to require a new low global warming potential refrigerant. R-1234yf has a GWP rating of 4, which is over 350X less than R-134a!

Politics and conspiracy theories aside, regulations have already been passed in Europe that will require some type of new refrigerant. The Europeans were considering CO2 (R-744) because it has the lowest GWP rating of all: One! But A/C systems that operate using CO2 require extremely high pressures (1,800 to 2,200 PSI versus 300 to 400 PSI for R-134a and R-1234yf) and are much more expensive to manufacture.

The auto makers had agreed on moving ahead with R-1234yf until Daimler (Mercedes-Benz) ran some tests that revealed R-1234yf could ignite under certain special conditions. Based on the test findings, Mercedes and Volkswagen said no to the new refrigerant. R-1234yf is slightly flammable, but according to the Society of Automotive Engineers (SAE), the new refrigerant is safe for automotive passenger car use. The risk of fire is extremely remote in case of an accident or refrigerant leak into the passenger compartment.

To read the official SAE press release, Click Here.

 .

HOW DOES R-1234YF COMPARE TO R-134A?

R-1234yf has cooling performance that is similar to R-134a but not quite as good. It is about 5 percent less efficient than R-134a. It is not a simple drop-in substitute for R-134a because it requires a slightly larger or more efficient condenser and a more robust leak-resistant evaporator (for safety). R-1234yf also requires a new type of compressor PAG oil, as well as new J2843 certified recovery and recycling equipment designed especially for the new refrigerant. And here’s the punch line: R-1234yf is significantly more expensive than R-134a ($120 per pound versus about $10 per pound).

For more information, see HFO-1234yf Technical Information - Honeywell

Other hydrocarbon and hydrocarbon-blend refrigerants (such as propane, butane and others) have also been considered, but would require some type of secondary loop cooling configuration and special safety features to keep the potentially explosive vapors away from the passenger compartment. Many states ban the use of flammable refrigerants in motor vehicles (except for use in refrigerated truck trailer cooling units).

R-134A WILL CONTINUE FOR CURRENT VEHICLES AND OLDER VEHICLES

As of this writing, there are no plans to eliminate R-134a as happened to R-12, or to require retrofitting older vehicles or current vehicles that have R-134a A/C systems to the new HFO-1234yf refrigerant. R-134a will remain in production to service existing A/C systems.

R-134a should only be used in R-134a systems, and should NOT be used to top off a R-1234yf system. Likewise, R-1234yf should NOT be used in an older R-134a or R-12 A/C system due to material compatibility and lubrication issues.

R-1234yf A/C systems will have their own unique service fittings (which are different from R-12 and R-134 fittings) to discourage accidental cross-contamination.

R-1234YF SERVICE PRECAUTIONS

Because R-1234yf is slightly flammable, an evaporator that is leaking MUST be replaced with a new unit. The installation of a used evaporator from a salvage vehicle is NOT allowed because there is a chance it might also leak, exposing the vehicle's occupants to potentially flammable vapor mixture.

Professional service equipment for R-1234yf includes a leak check feature built into the recovery and recharging machine. The equipment also includes a refrigerant identifier to make sure the vehicle's A/C system contains R-1234yf and not some other refrigerant.

If your a/C system is leaking, the leak MUST be fixed before the shop will recharge your A/C system with refrigerant.

R-1234yf NEW CAR APPLICATIONS

The first U.S. vehicle to use R-1234yf refrigerant was the 2013 Cadillac XTS. Cadillac also tried R-1234yf in the Cadillac ATS, but stopped only one month into production because of A/C compressor noise and vibration issues. Early production ATS models were recalled and retrofitted back to R-134a (which apparently works fine in an A/C system designed for R-1234yf).

For model year 2014, R-1234yf is used in the Jeep Cherokee, Chrysler 300, Dodge Ram 1500, and Dodge Charger, Challenger and Dart. It will also be used in the 2015 Chrysler 200.

Most auto makers are expected to have numerous R-1234yf applications by model year 2017 and beyond. Auto makers receive fuel economy credits for vehicles that are converted to R-1234yf, which helps them achieve the new higher Corporate Average Fuel Economy (CAFE) requirements.

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Update February 2015

R-1234yf Vehicle Applications:

Here is a list of late model vehicles sold in North America that are using R-1234yf refrigerant in their air conditioning systems:

BMW i3 Electric
Cadillac XTS (2013 and 2014)
Chevrolet Malibu
Chevrolet Spark EV (2014)
Chevrolet Trax
Chrysler 300 (2014)
Dodge Challenger (2014)
, Honda Fit EV (2013 and 2014)
Hyundai Santa Fe & i30
Ford Transit
Infinity Q50
Jeep Cherokee (2014)
Kia Sorento, Optima & Cadenza
Mazda CX-5
Mitsubishi Mirage
Range Rover and Range Rover Sport (2014)
Subaru BRZ, Forrester & Impreza

More Refrigerant Articles:

New Automotive Refrigerants

Alternative Refrigerants for R-12

Flammable Refrigerants

California proposes ban on R134a sales to motorists

Information about Retrofitting older vehicles with R-12 A/C systems to R-134a

Troubleshooting Air Conditioning Problems

How To Recharge Your Car's Air Conditioner

Refrigerant Contamination 

Refrigerant Resources:

HFO-1234yf Technical Information - Honeywell

Alliance for Responsible Atmospheric Policy (ARAP)

DuPont Refrigerants

EPA FAQs on Alternative Refrigerants

Alternative Refrigerants

Alternative Refrigerants For Your Vehicle 

As R-12 continues to disappear, the price of R-12 refrigerant continues to rise. So what do you recharge an older air conditioning system with if R-12 is unavailable?

DROP-IN ALTERNATIVES FOR R-12 REFRIGERANT?

Though a number of alternative refrigerants are marketed as "drop-in" replacements for R-12, there is really no such thing as a true drop-in replacement. The reason why is because Federal law prohibits the topping off A/C systems with ANY refrigerant that is chemically different from what is already in the system, unless all of the old refrigerant is first removed so the system can be converted to the alternative refrigerant.

There are, however, a number of alternative refrigerants that can be used in older vehicles with R-12 A/C systems, and most have been reviewed and approved by the EPA for retrofitting older R-12 A/C systems. Approved refrigerants must meet the EPA's SNAP (Significant New Alternatives Policy) criteria for environmental acceptability and usage.

NOTE: The SNAP rules prohibit the use of flammable refrigerants (propane, butane and similar hydrocarbons) in mobile A/C systems because of their hazardous nature, and the SNAP rules prohibit the use of any other refrigerants that contain ozone-damaging CFCs. for more information about flammable refrigerants, Click Here.

APPROVED ALTERNATIVE REFRIGERANTS

There are number of alternative refrigerants from which to choose. One is R-134a, which is the ONLY alternative refrigerant currently approved by all vehicle manufacturers for retrofitting older R-12 A/C systems. The vehicle manufacturers say R-134a will cool reasonably well in most R-12 A/C systems provided the proper retrofit procedures are followed. They also recommend R-134a because it is a single component refrigerant, unlike most of the alternatives which are actually BLENDS of two to more ingredients.

The vehicle manufacturers do not like blends because blends can undergo "fractionation." This is when the individual ingredients in a blend separate for various reasons. Fractionation can be caused by chemical differences between the refrigerants (lighter and heavier elements do not want to stay mixed), different rates of leakage through seals and hoses (smaller molecules leak at a higher rate than larger ones), and different rates of absorption by the compressor oil and desiccant. Fractionation is a concern because it can change the overall composition of the blend once it is in use, which can affect the performance characteristics of the refrigerant. Fractionation also makes it difficult to recycle a blended refrigerant because what comes out of the system may not be the same mix that went into the system.

If you would like to read a variety of different views on the subject of alternative refrigerants and retrofits, Click here.

The vehicle manufacturers also say limiting the alternatives to one choice (R-134a) simplifies things, reduces the risk of cross-contamination and eliminates the need for multiple recovery machines. EPA rules require a separate dedicated recovery only or recovery/recycling machine for each type of refrigerant serviced.

ALTERNATIVE REFRIGERANT BLENDS

Alternative refrigerants that have been found acceptable for automotive applications or are currently being reviewed by the EPA include the following blends:

• Free Zone (RB-276). Supplied by Refrigerant Gases, this blend contains 79% R-134a, 19% HCFC-142b and 2% lubricant.

• Freeze 12. Supplied by Technical Chemical, this blend contains 80% R-134a and 20% HCFC-142b.

• FRIGC (FR-12). Made by Intermagnetics General and marketed by Pennzoil, this blend contains 59% R-134a, 39% HCFC-124 and 2% butane.

• GHG-X4 (Autofrost & McCool Chill-It). This blend is supplied by Peoples Welding Supply and contains 51% R-22, 28.5% HCFC-124, 16.5% HCFC-142b and 4% isobutane (R-600a).

• GHG-HP. Also supplied by Peoples Welding Supply, this blend contains 65% R-22, 31% HCFC-142b and 4% isobutane (R-600a).

• Hot Shot\Kar Kool. Supplied by ICOR, this blend contains 50% R-22, 39% HCFC-124, 9.5% HCFC-142b and 1.5% isobutane (R-600a).

The suppliers of the alternative blends say their products typically cool better than straight R-134a in systems designed for R-12, and do not require changing the compressor oil or desiccant in some cases. Changing the desiccant to XH-7 is usually recommended if an R-12 system is converted to R-134a. The desiccant should also be replaced if a blend contains R-22 because R-22 is not compatible with XH-5 or XH-7 desiccant. The recommended desiccant in this case would be XH-9.

The suppliers of the alternative blends also insist the fractionation problem is exaggerated and do not foresee any major problems with recovering and recycling their products (recycling blends is currently illegal, but the EPA is reviewing its feasibility).

One supplier of these products say they sold several million pounds of their alternative refrigerant, so the public is accepting it.

MACS ALTERNATIVE REFRIGERANT FIELD STUDY

A field study of various refrigerants conducted by the Mobile Air Conditioning Society (MACS) in 2003 compared the cooling performance of R-12, R-134a and three blended refrigerants (Freeze 12, FRIGC and McCool Chill-It). The study found that all the alternative refrigerants (including R-134a) did not cool as well as R-12 in the vehicles tested (a 1990 Pontiac Grand Am and a 1987 Honda Accord). But the study did find that the blends outperformed R-134a in the Honda (but not the Pontiac). The increase in A/C outlet temperature with the different refrigerants ranged from less than a degree to almost 11 degrees.

ILLEGAL REFRIGERANTS

Another class of alternative refrigerants has also appeared on the scene: illegal refrigerants. Some products that have been introduced (OZ-12, HC-12a, R-176 and R-405a) do not meet the EPA criteria for environmental acceptability or safety. Flammable refrigerants such as OZ-12 and HC-12a that contain large quantities of hydrocarbons (propane, butane, isobutane, etc.) have been declared illegal for use in mobile A/C applications, but are still turning up in vehicle systems anyway because of their cheap price.

WARNING: Flammable refrigerants pose a significant danger to the occupants inside a vehicle should a leak occur. A spark from a cigarette or a switch can ignite the leaking refrigerant causing an explosion and turning the car into a bomb. It only takes about four ounces of a flammable hydrocarbon refrigerant such as propane or butane to create an explosive mixture inside a typical automobile passenger compartment.

Frontal collisions can also release the refrigerant if the condenser is damaged, which could result in a severe underhood fire causing extensive damage to the vehicle.

There is also a risk to service technicians and do-it-yourselfers who might encounter leaks while servicing a vehicle or operating recovery/recycling equipment.

Merely topping off an A/C system with a flammable hydrocarbon can make the entire charge of refrigerant flammable if the amount added exceeds a certain percentage: 10% in the case of an R-12 system and only 5% with R-134a! That is only three or four ounces of hydrocarbon depending on the overall capacity of the system.

Flammable refrigerants are used in some stationary applications as well as truck trailer refrigeration units because there is less risk of leakage or fire. Also, the amount of refrigerant is typically much less, only five or six ounces total instead of several pounds.

BOOTLEG REFRIGERANTS

Less dangerous but equally illegal is bootleg R-12 that is being smuggled into the U.S. from offshore. Though most of the industrialized nations have stopped manufacturing R-12 (production ended in the U.S. December 31, 1995), R-12 is still being made in some Third World countries including Mexico. Some of this product is finding its way past customs in mislabeled containers or concealed in various ways. The EPA warns that much of the refrigerant it has confiscated thus far is of poor quality, contaminated by air, moisture, R-22 and other substances. The EPA has worked with customs authorities and the FBI to make a number of arrests. Fines for violating the clean air rules can run up to $25,000 per instance.

Counterfeiting branded product is another scam that is being perpetrated to turn a fast buck in today's market. Cylinders of counterfeit Allied Signal Genetron R-12 have reportedly been turning up in various parts of the country. The cylinders do not contain R-12 but some "unknown" refrigerant. Allied Signal says the counterfeit boxes do not have cut-outs where lot numbers strapped on cylinders would appear and there are no bar codes or white painted stripes on the sides. The number "Q 1167" may also appear on the bottom of the packaging. The cylinders themselves may be marked with a pressure-sensitive decal whereas the genuine product has markings printed on the cylinder itself.

CONTAMINATED REFRIGERANT

The high price of R-12 has also lead to an increase in incidences of virgin R-12 being adulterated with other less expensive refrigerants. Most technicians assume a tank of virgin refrigerant is pure, but some are finding that is not the case. Some suppliers say they now test every single tank of refrigerant to make sure it contains the proper refrigerant and that the quality of the refrigerant meets specifications.

The primary threat of contamination, though, is that of accidentally cross-contaminating refrigerants when vehicles are professionally serviced. Because the law requires all refrigerants to be recovered, there is a potential risk of contaminating when recovery and recycling equipment is connected to a vehicle. The problem is compounded, many say, by the proliferation of alternative and illegal refrigerants.

The dangers of cross-contamination are the effects it can have on cooling performance and component reliability. R-12 and R-134a are not compatible refrigerants because R-134a will not mix with and circulate mineral-based compressor oil (which may lead to compressor failure). Nor is R-134a compatible with the moisture-absorbing desiccant XH-5, which is used in many R-12 systems.

Intermixing refrigerants can also raise compressor head pressures dangerously. Adding R-22 (which is used in many stationary A/C systems but is not designed for use in mobile A/C applications) to an R-12 or R-134a system may raise head pressures to the point where it causes the compressor to fail. Straight R-22 can cause extremely high discharge pressure readings (up to 400 or 500 psi!) when underhood temperatures are high. R-22 is also not compatible with XH-5 and XH-7 desiccants used in most mobile A/C systems.

R-134a also requires its own special type of oil: either a polyakylene (PAG) oil or a polyol ester (POE) oil. The OEMS mostly specify a variety of different PAG oils because some compressors require a heavier or lighter viscosity oil for proper lubrication (though General Motors does specify only a single grade of PAG oil for most service applications). The aftermarket generally favors POE oil because POE is compatible with both R-12 and R-134a and unlike PAG oil it will mix with mineral oil. Mineral oil, as a rule, should still be used in older R-12 systems.

SHOULD YOU USE AN ALTERNATIVE REFRIGERANT?

The use of alternative refrigerants in older R-12 vehicles will continue because in some cases there is no other option other than converting to R-134a. Vehicle manufacturers discourage using alternative refrigerants and recommend R-134a for retrofitting older R-12 systems.

DO NOT use any alternative refrigerant in a vehicle with a R-134a A/C system (most 1995 and newer vars and trucks). This is illegal and may cause cooling problems and/or compressor failure.

DO NOT use any alternative refrigerant in newer vehicles that have a R-1234yf A/C system. This is also illegal and may cause cooling problems and/or compressor failure.

To minimize the risk of refrigerant cross-contamination, the EPA requires that each type of refrigerant (including alternative blends) have unique service fittings (permanently installed) and proper labeling. The EPA also requires shops to use a separate dedicated recovery/recycling machine for R-12, R-134a and R-1234yf, plus one or more additional recovery only machines for any other refrigerants that might be used. For this reason, many shops choose to avoid blends. But fleets may find blends to be an acceptable alternative if they do not want to convert (or it would cost too much to convert) their vehicles over to R-134a.

To protect recycling equipment against cross-contamination or bad refrigerant, service facilities should use a refrigerant identifier to check every vehicle before it is serviced. An identifier can also help the shop monitor the quality of their recycled refrigerant as well as any virgin refrigerant that might be purchased.

The best advise is this: if you do not know what type of refrigerant is in your vehicle, take it to a shop that has a refrigerant identifier and have it checked. Intermixing different refrigerants can cause cooling problems as well as shorten the life of the A/C compressor.

REFRIGERANT CONTAMINATION ALERT!

As the use of alternative refrigerants grows, so does the risk of cross-contamination. A recent survey by the Florida EPA revealed some startling results. When they tested the refrigerant recovery tanks in about 100 shops, here is what they found:

Thirty-eight percent of the recovery tanks showed some type of contamination! Independent repair garages and service shops had the lowest rate of contamination, but it was still 32% (nearly one out of three). Used car dealers were the worst, with 71% of their recovery tanks (almost three out of four) showing signs of contamination.

Air contamination was the worst problem, being present in 22% of the tanks tested overall. But cross-contamination between R-12 and R-134a was also found in 15% of the tanks. The most cross-contamination (29%) was discovered in used car dealers.

RETROFIT TO r-134A OR NOT?

Use R-12 in all R-12 systems as long as it is available because R-12 provides the best cooling performance in these applications. There is no need to retrofit to R-134a or to use any other refrigerant as long as the system is cooling normally. But if your A/C system requires major repairs such as a new compressor or condenser, the cost to retrofit is justified.

Switching an older R-12 system to R-134a does not require a lot of modifications in most instances. Changing the accumulator or receiver-dryer, removing the old compressor oil and replacing the high pressure switch is generally all that is needed. For more information, consider purchasing the R134A RETROFIT GUIDE on this website.

OEM as well as aftermarket retrofit kits are now available for such conversions. But some vehicles (namely certain Japanese cars that have compressors with Viton compressor seals, or certain older Fords with compressors that can't handle higher head pressures or have small condensers) are not so easy to convert. Changing some of these vehicles over to R-134a requires extensive and expensive modifications. So for these applications an alternative refrigerant may be the best choice if R-12 is unavailable.

Down the road, a number of new alternative refrigerants have been developed that may replace R-134a. For more information about the changes that are coming and why these changes are being required, click here.

Click Here for info about A/C R134a Retrofit Guide 

 More Air Conditioning Articles:

R-1234yf

Flammable Refrigerants

Troubleshooting Air Conditioning Problems

Recharging Your Car's Air Conditioner

New Automotive Refrigerants (More changes are coming down the road)

California proposes ban on R134a sales to motorists

Information about Retrofitting older vehicles with R-12 A/C systems to R-134a

MACS Recommended A/C Service Procedures (PDF file - requires Adobe Acrobat Reader to view). 

Automatic Climate Control 

A/C Compressor Failures

PAG oil Recommendations

A/C Condenser Flushing

Troubleshoot Air Conditioning

Air Conditioning Repairs And Services

A/C COOLING PROBLEM?

The most likely cause of an automotive air conditioner cooling problem is no refrigerant in the system. If the refrigerant has escaped past a leaky compressor or O-ring seal, leaked out of a pinhole in the evaporator or condenser, or seeped out through a leaky hose, the leak needs to be identified and repaired before the system is recharged.

On many systems, the compressor will not turn on if the refrigerant is low because the "low pressure safety switch" prevents the compressor clutch from engaging if system pressure is low. This protects the compressor from possible damage caused by a lack of lubrication.

One of the first things you should check, therefore, is compressor engagement. If the compressors magnetic clutch is not engaging when the A/C is turned on, the problem may be a blown fuse or a wiring problem. If the fuse is blown, replacing it may restore cooling temporarily. But the underlying reason for the fuse blowing in the first place needs to be identified and corrected to prevent the same thing from happening again.

If the magnetic clutch is receiving voltage but is not engaging the compressor, the clutch is defective and needs to be replaced. If there is any evidence of leakage around the compressor shaft seal, the seal should also be replaced.

If the clutch works but fails to turn the compressor (the belt may squeal in protest!), the compressor has seized and needs to be replaced.

Compressor failures are usually the result of loss of lubrication, which in turn may be due to low refrigerant in the system, a blockage (such as a plugged orifice tube which prevents refrigerant and oil from circulating to the compressor), loss of lubricant due to leaks or improper service procedures (not adding oil to the system to compensate for oil lost through leakage or component replacement), or use of the wrong type of lubricant.

R-12 systems require mineral oil while R-134a systems require various types of PAG oil or POE oil. Using mineral oil in a newer R-134a system can cause serious lubrication problems as can using the wrong grade (viscosity) of PAG oil. Always follow the vehicle or lubricant manufacturers compressor oil recommendations.

The next thing you should check when troubleshooting a no cooling problem is system pressure. For this, you need a set of A/C service gauges. Attach your service gauges to the high and low service fittings. If both the high and low side pressure gauges read low, the system is low and needs recharging. But before any refrigerant is added, check for leaks to find out where the refrigerant is going.

AIR CONDITIONING PROBLEM: REFRIGERANT LEAKSAll vehicles leak some refrigerant past seals and through microscopic pores in hoses. The older the vehicle, the higher the rate of seepage. Newer vehicles have better seals and barrier style hoses so typically leak less than a few tenths of an ounce of refrigerant a year. But system capacities also tend to be smaller on newer vehicles, so any loss of refrigerant will have more of an adverse effect on cooling performance.
Various methods can be used to check for leaks. The telltale oil stains and wet spots that indicate leaks on older R-12 systems are less apparent on the newer R-134a systems because PAG lubricants are not as "oily" as mineral oil. This makes it harder to see leaks.
Leaks can be found by adding special dye to the system (available in pressurized cans premixed with refrigerant), an electronic leak detector, or plain old soapy water (spray on hose connections and watch for bubbles -- requires adding some refrigerant to system first and turning the A/C on). Once you've found a leak, repairs should be made prior to fully recharging the system. Most leak repairs involve replacing O-rings, seals or hoses. But if the evaporator or condenser are leaking, repairs can be expensive.

POOR COOLING PERFORMANCE
Diagnosing an A/C cooling problem is best done by connecting a gauge set to the high and low pressure service fitting on the system. Though poor cooling is often due to a low charge of refrigerant, it can also be caused by many other factors (see chart above).
How to tell if your A/C system needs refrigerant: look at the LOW pressure gauge reading when the engine is OFF. On an 80 degree day, the LOW gauge should read about 56 psi or higher if the A/C system contains an adequate charge of refrigerant. On a 90 degree day, the LOW side reading should be about 70 psi or higher. If the LOW gauge reading is less than this, the A/C system probably needs some additional refrigerant.
Refer to the vehicle manufacturer specifications for normal system operating pressures, and the total refrigerant capacity of the system. Most newer passenger car A/C systems do not hold much refrigerant (14 to 28 oz.), so you don't want to add too much if the system is low.
AIR CONDITIONER PROBLEM: INTERMITTENT COOLING

Evacuating the system with a vacuum pump will purge it of unwanted air and moisture. Evacuation should be done with a vacuum pump that is capable of achieving and holding a high vacuum (29 inches) for at least 30 to 45 minutes.

An A/C system that blows cold air for awhile then warm air is probably freezing up. This can be caused by air and moisture in the system that allows ice to form and block the orifice tube.
For best performance, an A/C system should contain less than 2% air by weight. For every 1% increase in the amount of air that displaces refrigerant in the system, there will be a corresponding drop of about one degree in cooling performance. More than 6% air can cause a very noticeable drop in cooling performance, and possibly cause evaporator freeze-up.
Air can get inside a system through leaks, by not evacuating the system prior to recharging it, and/or by recharging the system with refrigerant that is contaminated with air. Recovery equipment can suck air into the recycling tank if an A/C system contains air or if the system has a leak. For this reason, the refrigerant recovery tank on recycling equipment must be checked and purged daily. On some equipment, this is done automatically. But on equipment that lacks an automatic purge cycle, tank pressure and temperature has to be measured and compared to a static pressure reference chart.
Some refrigerant identifier equipment can detect air in the system as well as other contaminants. An identifier should be used to check the refrigerant before the system is serviced to prevent cross-contamination of recovery and recycling equipment.
Possible causes of intermittent cooling in a manual A/C system that might be caused by an electrical problem include:

Faulty low pressure cutout switch. This switch prevents the compressor from running if the refrigerant level is low. If the cutout switch is not reading correctly, it can prevent the compressor from coming on.

Faulty compressor clutch. The magnetic clutch on the compressor requires full battery voltage to engage. If the voltage to the clutch is low, or the clutch coils have too much resistance, or the air gap in the clutch is too great, the clutch may not engage to drive the compressor.

Faulty compressor clutch relay. Check to see if the relay is receiving voltage when the A/C is turned on. Also check the relay wiring and ground connections. If bypassing the relay with a jumper wire or routing battery voltage directly to the compressor clutch makes the A/C work, the relay is probably bad.

Faulty A/C control switch. The switch may be worn and not making good contact when it is turned on.
Some possible causes of intermittent cooling (or no cooling) on automatic A/C systems include all of the above, plus:

A problem in the control module or control head (this usually requires using a dealer scan tool to read fault codes and perform self-diagnostics).

A bad temperature sensor (an ambient air temperature sensor, interior air temperature sensor, evaporator temperature sensor, or sunload sensor). Again, a factory scan tool is usually required to perform diagnostics on the system.

AIR CONDITIONING PROBLEM: NOISE
Noise from the compressor usually means the compressor is on its way out. But noise can also be caused by cross-contaminated refrigerant (operating pressure too high), air in the system or the wrong type of compressor lubricant.
Noise can also be caused by hoses or other parts rattling against other components in the engine compartment. Check the routing of the hoses, support brackets, etc., to pinpoint the noise.
TROUBLESHOOTING AIR CONDITIONING ODOR
If a vehicles air conditioner blows out air that smells like the inside of old gym sneaker when the A/C is turned on, microbes are growing on the evaporator. Mold likes damp, dark places. Bacteria can also thrive under such conditions. Besides smelling bad, it can be unhealthy to breathe (ever hear of Legionnaires Disease?).
To get rid of the unwanted organisms, various chemicals can be sprayed on the evaporator directly or through the blower ducts or air intake. Many replacement evaporators have a special chemical coating that inhibits the growth of mold and bacteria. The drainage tubes that carry condensation away from the evaporator should also be inspected and cleaned.
A/C FLUSHING
If the compressor has failed, or the system is full of sludge or contamination, the condenser, evaporator and hoses should all be flushed with an approved flushing chemical (such as Dura 141b) to clean the A/C system. Flushing can help prevent repeat compressor failures and system blockages by dislodging and cleaning out sludge and debris. Replacing badly contaminated parts such as the condenser, accumulator or receiver-drier and orifice tube or expansion valve is another way to get rid of these contaminants, but flushing is usually a more practical and economical choice. Regardless of which approach you use, the orifice tube or expansion valve should always be replaced when contamination is found.
NOTE: Some types of compressors can be very difficult to flush completely. These include "parallel" flow condensers and those with extremely small passegeways. If contaminated, these types of condensers must be replaced to reduce the risk of a repeat compressor failure. Installing an in-line filter is also recommended for added insurance,
When a compressor fails, a lot of metallic debris is often thrown into the system. Most of this debris collects in the condenser where it can cause blockages that reduce cooling performance. If the debris is carried through the condenser and enters the liquid line, it can plug the orifice tube or expansion valve. This can block the flow of refrigerant and lubricating oil causing a loss of cooling and possible compressor damage. Debris can also migrate backwards from the compressor through the suction hose causing blockages in the accumulator or receiver-drier.
Another source of trouble can be debris from old hoses that are deteriorating internally. Tiny flakes of rubber can be carried along to the orifice tube or expansion valve and cause a blockage.
Sludge is usually the result of moisture-contamination. The blackish goo that results can damage the compressor and plug the orifice tube or expansion valve. The moisture-absorbing "desiccant" in the accumulator or receiver-drier is supposed to prevent this from happening. But the desiccant can only hold so much moisture. Once saturated, sludge begins to form. So you should also replace the accumulator or receiver-drier if the system is contaminated, has leaks or must be opened up for repairs.
Another reason for flushing is to remove residual lubricating oil from the system. This should be done when retrofitting an R-12 system to R-134a. It should also be done if the lubricating oil is contaminated or the system contains the wrong type of oil for the application. Flushing out the old oil can prevent oil overcharging, reduced cooling performance and/or lubrication incompatibility problems.
For added insurance after flushing, you can install a high side filter to protect the orifice tube or expansion valve from any residual debris that might still be in the system, and/or a second filter in the suction hose to protect the compressor.
R134A RETROFIT
As long as R-12 is available, there is no real reason to convert older vehicles to R-134a. That is because R-12 systems cool best when charged with R-12 refrigerant. But converting to R-134a does make sense if your A/C system requires major A/C repairs (such as a new compressor, condenser or evaporator). The extra cost involved to make the changeover to R-134a does not add that much to the total repair bill.
A basic retrofit procedure can be done one of two ways. The "Type 1" retrofit follows the OEM recommended procedure and generally involves removing all the old mineral oil from the system, replacing the accumulator or receiver-drier with one that contains a desiccant (X-7) which is compatible with R-134a, replacing O-rings (if required), installing or replacing a high pressure cutout switch and/or orifice tube (if required), then adding the specified PAG oil and recharging the system with R-134a. Federal law also requires the installation of R-134a fittings on the high and low service ports to reduce the chance of refrigerant cross-contamination the next time the vehicle is serviced, and labels that identify the system has been converted to R-134a. For more information, see the R134A RETROFIT GUIDE program featured on this website.
 Click on image for more info A "Type 2" procedure is more of a "quick and cheap" approach to retrofit. On many 1989 through 1993 vintage vehicles, the R-12 A/C systems can be converted to R-134a by simply recovering any of the R-12 that is left in the system (NOTE: it is illegal to vent refrigerant into the atmosphere!), adding POE oil (which is compatible with both types of refrigerant), and then recharging with R-134a.
NOTE: Type 2 conversions cannot always be done on some vehicles because their compressors may not be compatible with R-134a (any compressor with Viton seals has to be replaced). This includes original equipment compressors such as Tecumseh HR980, some Keihin compressors and some Panasonic rotary valve style compressors in older Nissan vehicles.

Durability is another concern. Because R-134a raises compressor discharge pressures and increases the compressors work load, some lightweight compressors may not be rugged enough to tolerate R-134a over the long haul. This applies to the Harrison DA6 and Ford FX-15 compressors. The Harrison DA6 can be replaced with a HD-6, HR-6 or HR-6HE compressor. The Ford FX-15 compressor can be replaced with a FS-10 compressor.

More Air Conditioning Articles:

Air Conditioning Inspection Checklist

Troubleshoot Automatic Climate Control System

A/C Cooling Problem: Blows Warm Air Only No Cool Air

How To Recharge Your Car's Air Conditioner

A/C Service Equipment: What's Required To Service Today's Vehicles

Air Conditioning Service Best Practices (Procedures a repair shop should follow when servicing your A/C system)

MACS Recommended A/C Service Procedures (pdf file) 

MACS 2004 A/C Technical Update

A/C Compressor Failures - May 2003

PAG oil recommendations

A/C Condenser Flushing

A/C Update: MACS Report - Jan 2001

OEM Service Note from MACS Convention - Jan 2000

Update on R134a Retrofit - Feb 2000

Alternative Refrigerants

HFO-1234yf Refrigerant

California proposes ban on R134a sales to motorists