Removing and Installing Compressor - GT3
Removing And Installing Compressor - GT3
Removal
1. Remove the cover above the heating/ air-conditioning system. Remove the refrigerant by suction using the service unit.
2. Disconnect the battery and cover terminal or battery. Remove the complete air cleaner assembly.
3. Just loosen belt pulley for hydraulic pump. Relieve the drive belt at the tensioning pulley and remove the belt.
4. Unclip wire from the air flow sensor on the expansion tank of the hydraulic pump.
5. Remove belt pulley for hydraulic pump and remove oil filler necks from support.
6. Undo fastening screws on the expansion tank (2 M8 screws) and the hydraulic pump (3 M8 screws and one M6). Pull the expansion tank with hydraulic pump and connected lines up out of the fastening bracket and set down on the right-hand side.
7. Remove holder for oil filter console (2 screws M8 and M6). Just loosen lower M8 screw and lift holder out (bore is slotted).
8. Undo the compressor from the console (3 screws).
NOTE: The intake distributor with throttle body can be swung upward as far as it will go for better accessibility to the front screw. To do this, both inner hose clamps must be removed.
9. Lift the compressor with spacer sleeve and fastening screws out of the bracket and carefully remove to the rear. Disconnect the electrical plug connection.
10. Undo the refrigerant lines at the compressor. Immediately close connections and lines with plugs so that they are air-tight.
Installation
NOTE: New compressors are pressurised and are filled with the required amount of oil for the refrigerant circuit. The remaining oil quantity in the individual components must therefore be taken into account.
1. First, open the cap on the high-pressure side and relieve the pressure from the compressor (A).
2. Open the oil filler screw (B) on the compressor.
3. Empty approx. 80 cb.cm of refrigerant oil out of the compressor and into a measuring glass. The remaining quantity of oil (approx. 120 cb.cm ) remains in the compressor.
NOTE: Refrigerant oil from the compressor or refrigerant oil removed by suction from a previously run air-conditioning system may no longer be used (special-category waste).
4. Tightening torque for oil filler screw.
M10 x 1 26 ... 36 Nm
Always replace the sealing ring.
5. Tightening torque for refrigerant line screws.
M8 x 32 23 Nm
Use fastening screws from the new compressor. Replace O-rings and wet the new rings with refrigerant oil.
6. Do not remove the plugs for the lines and compressor connection until shortly before installation.
7. Install compressor with lines.
NOTE:There is a spacer sleeve between the compressor and the console. This spacer sleeve must be glued onto the compressor with instant adhesive before installation. Engage electrical connection and install compressor with fastening screws.
8. Install expansion tank with hydraulic pump and fasten oil filler necks to holder.
9. Tightening torque for the compressor fastening screws on the console.
M8 screws 23 Nm
Fastening screws for hydraulic pump and belt pulley expansion tank.
M8 screws 23 Nm (17 ftlb.)
M6 screws 10 Nm (7.5 ftlb.)
10. Mount belt pulley for hydraulic pump and fit drive belt.
11. Fasten both hose clamps on the intake distributor and clip in wire for the air flow sensor.
12. Install holder for oil filter console and air cleaner assembly. Connect the battery.
13. Fill the heating/air-conditioning system with refrigerant.
Running-in regulations for new compressor
NOTE: Fill the air-conditioning system (fluid) via the high-pressure side from the refrigerant circuit with the engine "OFF".
1. If possible, all air outlet nozzles "OPEN", circulating air "CLOSED".
2. Start the engine and allow idle speed to stabilise (approx. 5 seconds).
3. Set the fan to max. output.
4. Switch on the air-conditioning system (AC switch) and allow it to run uninterrupted for at least 2 minutes at 1500 rpm.
5. After 2 minutes uninterrupted compressor operation time, the oil distribution in the air-conditioning system is completed and the compressor can be run up to the max. engine speed.