Condenser HVAC: Service and Repair

Condenser, removing and installing


NOTE:
- The connection of the refrigerant lines differs, depending on engine type.
- The construction of the accumulator differs, depending on model year and engine type.
- Keep accumulator closed as long as possible; do not remove caps until just before installing. The accumulator contains a desiccant which will become saturated with moisture in a shod time if accumulator is left open. This makes the accumulator unusable.


Removing
- Discharge A/C refrigerant system:
- Remove complete front bumper:
- Bring the lock carrier into service position:
- Remove charge air cooler or the secondary air injection pump.

Version "1" (with bolted connection and bracket), removing







- Unscrew bolts -A-.
- Remove refrigerant line -B- (tightening torque: 40 Nm).


NOTE:
- Replace both O-Ring-seals (17.2 mm x 1.8 mm).
- Seal all open connections.
- Install spring -C- so it is positioned against marking on refrigerant hose and engaged on bracket.







- Remove hexagon nuts -D-.
- Remove accumulator with bracket.
- Remove refrigerant line -E- (tightening torque: 40 Nm).


NOTE:
- Install refrigerant lines free of stress and make sure there is enough clearance to other components.
- When installing the accumulator in the bracket, always install insulation -F-.


Version "2" (with block and bolt connection), removing







- Remove hexagon nuts -A- (tightening torque: 8 Nm).
- Remove bolts -B- (tightening torque:25 Nm).
- Remove refrigerant line -C- (tightening torque: 40 Nm).
- Remove refrigerant line -D-.


NOTE:
- Replace O-rings -E- (17.2 mm x 1.8 mm) and -F- (16.7 mm x 1.8 mm).
- Seal all open connections.







- Remove hexagon nuts -A-.
- Loosen clamp -B-
- Remove bracket -C-
- Remove hexagon nuts -D- (tightening torque: 8 Nm).


NOTE:







- Only install accumulator with insulation -E-.
- Install spring -F- so it is positioned against marking on refrigerant hose and engaged on bracket


Version "3" (with two block connections), removing







- Remove bolts -A- (tightening torque 25 Nm) and remove refrigerant lines -B- and -C-.


NOTE:
- Replace both O-Ring-seals -D- and -E- (16.7 mm x 1.8 mm).
- Seal all open connections.
- The connection on the accumulator can be marked with "IN" (from evaporator) and "OUT" (to compressor).







- Remove bolts -A- (tightening torque: 8 Nm).
- Loosen notch on bracket for accumulator -B- from body
- Remove accumulator with bracket.
- Loosen screw -C- (tightening torque 8 Nm) and remove accumulator from bracket -D-.

Installing (all models)
Before installing accumulator:


NOTE:
- When tightening refrigerant lines to accumulator hold accumulator e.g. with oil filter strap (to avoid accumulator from turning).
- Install refrigerant lines free of stress and make sure there is enough clearance to other components.
- Keep accumulator closed as long as possible; do not remove caps until just before installing. The accumulator contains a desiccant which will become saturated with moisture in a short time if accumulator is left open. This makes the accumulator unusable.
- Removed accumulator contains refrigerant oil which must be restored to the refrigerant system (with new accumulator).
- The adaptation of the oil capacity depends on the type of report:
-- For example if the accumulator was damaged (no refrigerant escaped, no moisture or dirt entered the system), the air conditioning system can be repaired by weighing the old and the new accumulator: Fill new accumulator with refrigerant oil, until the weight of the removed accumulator is reached.
-- If an undefined amount of refrigerant oil escaped or dirt and moisture entered the system, clean refrigerant circuit with compressed air and nitrogen


Installation is in reverse order of removal, observe notes and tightening torque for respective version (see removing notes)
- Install all removed components again.
- Evacuate and recharge refrigerant circuit.