Compressor HVAC: Service and Repair

Removing And Installing Air-Conditioning Compressor

Preliminary work

1. Draw off and dispose of refrigerant in the air-conditioning system in accordance with regulations.
2. Remove left front wheel.
3. Remove engine guard.
4. Remove drive belt.

Removing air-conditioning compressor

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












1. Remove the connector on the compressor from the support -arrow A-, release it -arrow a- and disconnect it -arrow B-.







2. Remove the refrigerant lines at the compressor.







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







6. Remove the air-conditioning compressor downward and to the left and turn the air-conditioning compressor.

Installing air-conditioning compressor

ATTENTION: Risk of damaging the air-conditioning compressor.

- The engine must not be started until the air-conditioning system has been filled.

NOTE:
- If the air conditioning compressor is blocked/seized up, then additional steps must be carried out to ensure the operation of the air conditioning.
- 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. 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. Always replace the sealing ring for the oil filler screw. Tightening torque 19 ftlb.
5. Use fastening screws from the new compressor. Replace O-rings and wet the new rings with refrigerant oil.







6. Position the bushing on the compressor, push compressor in sideways.







7. Position the steering hydraulic line and compressor.
8. Screw down the compressor and steering hydraulic line with the fastening screws -3- Tightening torque 17 ftlb. and -4- Tightening torque 34 ftlb.
9. Do not remove the plugs for the lines and compressor connection -1- and -2- until shortly before installation.







10. Position refrigerant lines and screw on securely. Tightening torque 15 ftlb.







11. Push on connector -arrow B-, until lug -arrow a-clicks into place and insert into the support on the compressor -arrow A-.

Work steps for blocked/seized up air conditioning compressor

1. Remove desiccator from the condenser.
2. Check the desiccator for wear/chips.

If there is wear/chips:
3. Remove the refrigerant line on the compressor - condenser.
4. Clean the refrigerant line on the compressor-condenser with compressed air.
5. Replace the condenser with desiccator.
6. Install the refrigerant line on the compressor-condenser.

If there is no wear/chips:
- Replace the desiccator.

Subsequent work

1. Install drive belt
2. Fill refrigerant on the air conditioner in accordance with regulations.
3. Open air exhaust nozzles on the dashboard, and set fan to at least 75 %.
4. After allowing the system to stabilise at idle speed (approx. 5 sec.), switch on air conditioner and allow the engine to run uninterrupted for at least 2 minutes at 1500 rpm.
5. Switch off the air conditioner again. Do not drive until the air conditioner has been filled.
6. Install engine guard.
7. Mount left front wheel.