Compressor HVAC: Service and Repair

Removing and Installing Air-Conditioning Compressor







WARNING: Danger of injury: Safety regulations must be strictly observed when working on air-conditioned vehicles and handling refrigerant.

- Refer to, Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a.
- Refer to, Safety regulations for extraction and filling systems.
- Refer to, Instructions for repairing air-conditioning systems and storing spare parts.

Removing Air-Conditioning Compressor
- Remove engine guard.







1. Remove engine cover -arrow A-.
2. Unscrew the fastening screws -a- and remove both covers -arrow B-.







3. Release connector -arrow A- and pull out -arrow B-.
4. Release air cleaner cover -arrow C- and pull upwards -arrow D-.







5. Release fastening clamp -A- and pull intake hose off throttle body -arrow B-.
6. Pull intake hose away to the right -arrow C-.
7. Release vent hose -arrows D- and pull it off -arrow E-.
8. Remove air cleaner cover with intake hose.

NOTE:
- Mark the running direction on the top before removing the drive belt.
- Only screw the pressure screw in far enough to remove the drive belt. Otherwise, the tensioning roller housing may be damaged.







9. Mark the running direction -b- on the drive belt.
10. Slacken the tensioning roller with the pressure screw (M8 x 50) -c- (-arrow A-) and remove the tensioning belt -arrow B-.







11. Undo fastening screw -1-.
12. Turn the belt pulley -arrow A-, then unscrew the fastening screws -2- and remove through the openings in the belt pulley.
13. Take out steering servo pump and remove from the work area -arrow B-.







14. Unscrew fastening screws -3- and pull out the two refrigerant lines -arrow-.
15. Close off the connections and lines immediately using suitable plugs -b & c-, then move the lines out of the work area.
16. Release connector (for reasons of accessibility) using a suitable tool -d- (-arrow A-) and pull it off (-arrow B-).







17. Unscrew fastening screws -4 & 5- and take out the air-conditioning compressor by pulling it to the side and upwards -arrow-.

Installing Air-Conditioning Compressor

WARNING: Risk of damaging the compressor: The engine must not be started until the air-conditioning system has been filled.

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.
- 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).







1. First, open the plugs on the high-pressure side and relieve the pressure from the compressor -b-.
2. Open the oil filler plug -6- on the compressor.
3. Empty approx. 80 Cu.cm of refrigerant oil out of the compressor and into a measuring glass. The remaining quantity of oil (approx. 120 Cu.cm) remains in the compressor.

4. Replace the sealing ring for the oil filler plug and tighten the oil filler plug -6-. Refer to tightening torques.
5. Use the fastening screws from the new compressor. Replace O-rings and wet the new rings with refrigerant oil.







6. Position the bushings at the front of the compressor.
7. Position compressor in installation position -arrow- and secure with the fastening screws -4 & 5-. Refer to tightening torques.







8. Connect plug -arrow A- until locking tab -B- engages.
9. Do not remove plugs -b & c- until shortly before installation.
10. Connect the two refrigerant lines -arrow C- and secure with the fastening screws -3-. Refer to tightening torques.







11. Position steering servo pump in installation position -arrow A- and screw in the fastening screw -1-, but do not tighten it.
12. Turn the belt pulley -arrow B-, then screw the fastening screws -2- in through the openings in the belt pulley and tighten them. Then tighten the fastening screw -1-. Refer to tightening torques.







13. Check installation position and direction of rotation -b- of the drive belt.
14. Unscrew the pressure screw -c- and tension the drive belt -arrow-.







15. Insert the vent hose -arrow A- until you feel the locking tabs -B- engage.







16. Insert the air cleaner.
17. Connect the intake hose to the throttle body -arrow A-.
18. Fit the cover of the air cleaner housing -arrow B- into position and secure with the retaining clips -arrow C-.
19. Tighten the fastening clamp -D-.







20. Connect plug -arrow A- until locking tab -B- engages.







21. Fit engine cover -arrow A- until locking tabs are felt to engage.
22. Fit the covers -arrow B- and secure with the fastening clips -a-.

- Fill refrigerant on the air-conditioning system in accordance with regulations. Refer to, Adding refrigerant and removing by suction.
- Open air outlet nozzles on the instrument panel, and set blower to at least 75 %.
- After allowing the system to stabilize at idle speed (approx. 5 sec.), switch on air conditioning and allow the engine to run uninterrupted for at least 2 minutes at 1500 rpm.
- Switch off the air-conditioning system again. Do not drive until the air-conditioning system has been filled.
- Fit engine guard.

Tightening Torques