Ok... so after the last false start I finished this up today... another new dryer, vacuumed, checked for leaks, and charged with 1100 grams of R134A. Now I have nice cold air - the clutch cycles on my car at 48*F vent temp and the clutch is cycling.

The reconfigured electric fans work well too. However I think I need to clean up the connections at the relays or put in bigger wire or something, they're getting really really hot, so hot I could see a fire starting. Odd since they don't draw that much juice.

-J

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1991 350SDL. 230,000 miles (new motor @ 150,000).

Tesla Model 3. 136,000 miles. Been to 48 states!
Past: A fleet of VW TDIs.... including a V10,a Dieselgate Passat, and 2 ECOdiesels.
2014 Cadillac ELR
2013 Fiat 500E.

I wired both fans together on high thru a 40 amp relay and its overheating also. Thinking of wiring each fan on its own relay and see if that helps. I have the same model car as you.
How hard was it to flush the A/C system? It's charged with Duracool and I'm thinking of going back to R134A. I've never flushed a system before.

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1991 350SDL 350k+ miles

Flushing these cars is a major PITA because of the placement of the expansion valve. You have to take most of the driver's side dash apart to get at it, and even then access is tight. You'll need crow's foot wrenches. One suggestion I have is that when you install it don't tighten the top 2 connections until you have the suction line at the bottom started... with the top 2 (evaporator) connections tight it's a 2 man job to hook up the suction line... one person turning the large fitting while another holds the line with vice grips and pushes it up into place.

To flush the system completely you need to remove the TX valve, and also remove the condenser. To remove the condenser the radiator has to come out. With the condenser out you can remove the fan shroud and fans. Be sure to oil the fan motors while you have this access.

Here's a video I shot of the results.

https://www.youtube.com/watch?v=G7SGo-z1Umw

I'm sure it would be colder with R12, but I think it will make due for now. I used Ester oil, so I could go to R12 or R152 later.

-J

__________________
1991 350SDL. 230,000 miles (new motor @ 150,000).

Tesla Model 3. 136,000 miles. Been to 48 states!
Past: A fleet of VW TDIs.... including a V10,a Dieselgate Passat, and 2 ECOdiesels.
2014 Cadillac ELR
2013 Fiat 500E.