Compressor HVAC: Service and Repair

Removing and Installing Air Conditioning Compressor







WARNING: Danger of injury: Safety regulations should be strictly observed when working on air-conditioned vehicles and dealing with 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.

Remove Air-Conditioning Compressor
- Siphon the refrigerant off the A/C and discard according to the instructions. Refer to, Adding refrigerant and removing by suction.
- Remove left front wheel.
- Remove underbody - engine cover.
- Remove drive belt.







1. Pull connector on the compressor out of the holder and disconnect.







2. Remove the refrigerant lines on the compressor.







3. Immediately lock connections and lines with the appropriate plugs -1, 2-.
4. Unscrew the three fastening screws -3, 4- from the air conditioning compressor.
5. Pull off the steering hydraulic line to the front.







6. Remove the air conditioning compressor downwards to the left, twist air conditioning compressor.

Installing Air-Conditioning Compressor

WARNING: Danger of damage to the compressor: The engine must only be started when the A/C has been filled.

NOTE:
- New compressors are pressurized 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 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 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. Completely replace sealing ring for oil filler screw. Refer to tightening torques.
5. Use fastening screws from the new compressor. Replace O-rings and wet the new rings with refrigerant oil.







6. Position bushing on the compressor, insert compressor sideways.







7. Position steering hydraulic line and compressor.
8. Tighten compressor and steering hydraulic line with the fastening screws -3- and -4-. Refer to tightening torques.
9. Do not remove the plugs for the lines and compressor connection -1- and -2- until shortly before installation.







10. Position and screw down refrigerant lines. Refer to tightening torques.

- Installing drive belt.
- Fill the A/C with refrigerant according to the instructions.
- Open air vents on the instrument panel, adjust fan to at least 75%.
- Switch on A/C after idle speed stabilization (approx. 5 sec) and allow the engine to run for at least 2 minutes without interruption with an engine speed of 1500 Per min.
- Switch A/C off again. Driving operations can only be interrupted after the system has been filled successfully.
- Assemble underbody - engine cover.
- Assemble left front wheel.

Tightening Torques