Compressor HVAC: Service and Repair

Compressor, replacing

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Draining the air conditioning (A/C) system

Warning! Follow the safety instructions for work on air conditioning systems. See: Refrigerant, safety regulations Technician Safety Information.

Read the instructions covering slow and fast leaks. See: Oil Air Conditioning (A/C) System, Filling

Caution! Always use new O-rings lubricated with compressor oil.

Note! Always plug the pipes and connections when working on the climate control system.

Drain the air conditioning (A/C) system. See : Refrigerant, draining Refrigerant, Draining.
Remove the drive belt.

Removing the engine cooling fan
Remove the engine cooling fan (FC). See Engine cooling fan (FC), replacing, B8444S Service and Repair.

Removal

Removing electrical connectors and pipes/hoses to the compressor




Hang the lower coolant hose (1) to one side.

Remove:
- the 2 x connectors (2)
- the hose/pipe connections to the compressor and push them to one side.

Hint: Plug the terminals of the compressor using the transport plugs from the new compressor.

Removing the compressor




Remove the lower mounting screw (1) at the pulley. The screw can be reached from underneath after the splashguard for the engine has been removed. The screw is in the right hand corner of the sub-frame.

Note! The screw cannot be removed from this position.

Remove:
- the screw (2) underneath the compressor hose/pipe terminals
- the upper mounting screw (3) at the pulley.

Note! This screw is longer than the other two screws.




Withdraw the compressor slightly. Remove the lower left-hand mounting screw.
Remove the compressor with the connectors turned outwards (as illustrated).

Installation

Note! For tightening torques, see: [1][2]Body and Frame

Installing the compressor




If necessary fill or check the oil in the compressor. See Oil Air Conditioning (A/C) System, Filling
Install the compressor with the connectors turned outwards (as illustrated). Position the compressor in the sub-frame.
Install the lower, left hand mounting screw.

Caution! Ensure that the electrical cables are not trapped behind the compressor. The electrical cables must be pulled in tight to the compressor under the pipe/hose connectors.

Install:
- the compressor with 3 x M8 screws. Tighten
- the pipes/hoses to the compressor
- the connectors
- the lower coolant hose.

Finishing

Installing components
Install the drive belt.

Note! Do not install the skid plate yet.

Install the engine cooling fan. See: Engine cooling fan (FC), replacing, B8444S Service and Repair.

Function check with leak tracing
Vacuum pump the air conditioning (A/C) system. See: Vacuum pumping Vacuum Pumping.
Fill the air conditioning (A/C) system with refrigerant. See: Refrigerant, filling Refrigerant, Filling.
Leak trace the air conditioning (A/C) system. See: Leak tracing, fluorescent tracing agent / UV lamp Leak Tracing, Fluorescent Tracing Agent/UV Lamp or Leak tracing, electronic leak tracer Leak Tracing, Electronic Leak Tracer.

Checking the performance
Carry out a performance test of the climate control unit. See Climate system, performance test Climate System, Performance Test.