Complete new AC system replacement finished.

The complete replacement of the 97 Legacy AC system was successful, running for a week in hot weather.

Everything was pretty straightforward and easy, except the evap coil.

The only available part did NOT have the correct threaded end to match the original low pressure suction hose. The large aluminum tube is 5/8 diameter.

I had to decide whether to replace the hose, or modify the evaporator end. I purchased a Mcmaster Yor-lok (2 compression cones on each end, like a swage-lok) compression fitting 5272K228 for $13 (http://www.mcmaster.com/nav/framewor...ew=2D&size= 2)

cut the two ends of the old and new evaporator outlets, cleaned up the ends and connected them.

It works very well. Note the cut off end to the side of the pic. I had to think about it a week before I cut into a $200 brand new part. I figured it was worth the risk since it should be subject to not much more thatn 50 psi.

When installing the swage-lok, I cleaned up the tube ends, lubed the parts with PAG oil, and crimped it just tight enough to convince me. The aluminum tubes are quite thickwall and somewhat malleable, so combined with the brass it got a good seal. I was worried about the weight a little, but it's not an issue since the connector end is supporte when put in the case and the car.

The large aluminum tube had to be bent a little, but I avoided bending near the welds or existing turns. It had to be extended a little to stick out far enough through the firewall.

This is a zexel system, all parts except evap from rockauto, evap from partsbin. Odd thing was that no single source could supply everything. Maybe that is smart of them, since they woudl get a lot of returns because the stuff wouldn't fit without fixes like this one.

Removing and replacing the evap is a piece of cake, compared to say a Chev. I used an AC shop to diagnose the system originally, discharge, and then evacuate and recharge the new system.

An added bonus, the new receiver has a sightglass. R134 behaves differently there than R12, kind of foamy when running.

It blows frigid. Well worth the effort. On to the O2 sensor and then the struts! After I paint the living room.