Flushed with Selig - Kwik Solv. I buy it in gallon containers. Our shop air is dried to -40f dewpoint. Its dry. Flushed several times to get that damn dye out of the system. Then chased it with plenty of air. Flushed every component separately.

Both aux fans were running the correct direction. In fact I removed the plug off the temp sensor which makes them run at high speed. Fan clutch was working properly. AT one point I even had a squirrel cage blower sitting in front of the car adding more air flow.

I have proper gear - refrigerant recovery & recycling equipment and 2 vacuum pumps, electronic vacuum gauges - the works. Pulled a vacuum to 95 microns for 4 hours. Let it stand over night. Still good in the morning. Recharged with virgin R12.

I should have left in the original expansion valve. It worked really well. Its such a *tch to get at it I did the usual - replace while I am in there routine. I should have listened to my intuition.

The way I see it - its gota be the Ex valve. There is nothing else in the system that could cause the problem. Compressor is obviously good - what else is there? There is only really two components in the system - compressor and Ex valve. The rest is just tubing or plumbing. Not much to go wrong. I dont think the valve is bad, I think it is set wrong. I had considered cutting a slot in the adjuster so I could turn it after it is installed. But I didn't.

Oh well.

__________________
I got too many cars!! Insurance eats me alive. Dave

78 Corvette Stingray - 3k
82 242 Turbo Volvo - Manual - 270k
86 300e 5 speed manual - 210k
87 420sel - 240k
89 560sl - 78k
91 420sel - 205k
91 560sel - 85k
94 GMC Suburban - 90k
97 Harley Davidson Heritage Softail - 25k
00 GMC Silverado 1 ton 30k