Compressor HVAC: Service and Repair
WM 873419 Removing and installing air-conditioning compressor
Tools
Technical values
Preliminary work
1. Draw off and dispose of refrigerant in the air-conditioning system in accordance with regulations. => 870317 Removing refrigerant by suction and filling
2. Remove front left wheel. => 440519 Removing and installing wheel - section on "Removing"
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
3. Remove left wheel housing liner. => 505619 Removing and installing front wheel housing liner - section on "Removing"
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
4. Remove left air cleaner housing. => 242519 Removing and installing air cleaner housing - section on "Removing"
5. Remove engine guard. => 108019 Removing and installing engine guard - section on "Removing"
6. Remove drive belt. => 137819 Removing and installing drive belt - section on "Removing"
Removing air-conditioning compressor
WARNING
Danger of injury. Safety regulations should be strictly observed when working on air-conditioned vehicles and dealing with refrigerant.
-> => 80 Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a
-> => 80 Safety regulations for extraction and filling systems
-> => 80 Instructions for repairing air-conditioning systems and storing spare parts
Installation position of air-conditioning compressor
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
1. Seal lines -1 and 2- on the PDCC reservoir with hose clamps -3- to prevent them from leaking.
Sealing lines on the PDCC reservoir
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
2. Unscrew fastening screws -1- and unclip lines -2 to 5- at the line bracket -arrows-.
Disconnecting lines on the air-conditioning compressor
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
3. Unscrew fastening nuts -1- and push line bracket -2- with PDCC lines downwards -arrow-.
Removing line bracket for PDCC lines
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
Information
- Coolant hoses that come into contact with Pentosin must be cleaned thoroughly with water immediately.
- Replace visibly swollen coolant hoses.
4. Disconnect lines at the tandem pump.
4.1. Unscrew banjo bolt -1- and remove sealing rings -2-.
4.2. Carefully press line -3- to one side -arrow A-.
Information
The line can only be removed fully together with the air-conditioning compressor.
4.3. Unscrew union nut -4- and carefully pull line -5- down slightly -arrow B-.
Disconnecting lines at the tandem pump
5. Pull connector on air-conditioning compressor out of the holder -arrow A- , release it -arrow a- and then pull it off -arrow B-.
Pulling off connector
6. Unscrew fastening screws -1- and pull off refrigerant lines -2 and 3- ( -arrow- ).
Disconnecting refrigerant lines on the air-conditioning compressor
7. Loosen air-conditioning compressor.
7.1. Immediately close off connections and lines with suitable plugs -1 and 2-.
Loosening air-conditioning compressor
7.2. Undo fastening screws -3-.
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
7.3. Remove line bracket -1- ( -arrow- ).
Removing line bracket
7.4. Unscrew fastening screw -4- and support the air-conditioning compressor with your hand.
Loosening air-conditioning compressor
8. Remove air-conditioning compressor.
8.1. Carefully press lines -1 and 2- outwards -arrows A-.
8.2. Turn the air-conditioning compressor -3- ( -arrow B- ) and remove it between the two lines -1 and 2- ( -arrow C- ).
Removing air-conditioning compressor
Installing air-conditioning compressor
NOTICE
Too much refrigerant oil in new air-conditioning compressor.
- Risk of damage to air-conditioning components.
-> Do not start engine.
-> Do not tow the vehicle.
Information
- If the air conditioning compressor is blocked/seized up, then additional steps must be carried out to ensure the operation of the air conditioning. => 873419 Removing and installing air-conditioning compressor - section on "Information"
Information
- New air-conditioning compressors are pressurised and 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).
Information
The union nut on the hydraulic line must be tightened to the specified tightening torque using the following tools.
- Joint from the set socket wrench 9490
- Ring wrench insert ring wrench insert Nr.98-4
1. Open the cap on the high-pressure side and relieve the pressure from the air-conditioning compressor -A-.
2. Open the oil filler screw -B- on the air-conditioning compressor.
Cap and oil filler screw
3. Correct the refrigerant oil quantity in the air-conditioning compressor.
3.1. Collect the refrigerant oil from the compressor in a measuring glass.
3.2. 140 cm3 of this refrigerant oil must be filled back into the air-conditioning compressor.
4. Always replace the sealing ring for the oil filler screw. => Tightening torque: 26 Nm (19 ftlb.)
5. Use fastening screws from the new air-conditioning compressor. Replace O-rings and coat the new rings with refrigerant oil.
6. Position bushings on the air-conditioning compressor.
7. Fit air-conditioning compressor.
7.1. Carefully press lines -1 and 2- outwards -arrows C-.
7.2. Insert the air-conditioning compressor -3- through the two lines -1 and 2- ( -arrow A- ) and turn to place it in installation position -arrow B-.
Fitting air-conditioning compressor
8. Secure air-conditioning compressor.
8.1. Position air-conditioning compressor and screw in fastening screw -4- but do not tighten yet.
Securing air-conditioning compressor
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
8.2. Insert line bracket -1- ( -arrow- ) and position it correctly.
Inserting line bracket
8.3. Screw in fastening screws -3- but do not tighten yet.
Securing air-conditioning compressor
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
8.4. Insert line -5- into the tandem pump -arrow A- and screw in union nut -4- but do not tighten it.
Securing lines on tandem pump
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
8.5. Position line -3- on the tandem pump -arrow B- and screw in banjo bolt -1- with new sealing rings -2- , but do not tighten it.
8.6. Tighten fastening screws -3 and 4-. => Tightening torque: 23 Nm (17 ftlb.) => Tightening torque: 46 Nm (34 ftlb.)
Securing air-conditioning compressor
8.7. Do not remove stoppers -1 and 2- for the lines and air-conditioning compressor connection until shortly before installation.
8.8. Secure line -5- with the union nut -4-. => Tightening torque: 32 Nm (24 ftlb.)+/-4 Nm (+/-3 ftlb.)
Securing lines on tandem pump
8.9. Secure line -3- with the banjo bolt -1-. => Tightening torque: 35 Nm (26 ftlb.)
9. Fit refrigerant lines -2 and 3- with new sealing rings on the air-conditioning compressor -arrow- and secure with the fastening screws -1-. => Tightening torque: 20 Nm (15 ftlb.)
Securing refrigerant lines on air-conditioning compressor
10. Plug in connector -arrow B- until the locking lug -arrow a- engages securely and press it into the holder on the air-conditioning compressor -arrow A-.
Plugging in connector
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
11. Push line bracket -2- with PDCC lines onto the threaded bolts -arrow- and secure with the fastening nuts -1-.
Securing line bracket for PDCC lines
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
12. Clip lines -2 to 5- into the line bracket -arrows- and secure with the fastening screws -1-.
Securing lines on air-conditioning compressor
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
13. Remove hose clamps -3- from the lines -1 and 2- on the PDCC reservoir.
Removing hose clamps from lines on PDCC reservoir
Work steps for blocked/seized up air conditioning compressor
1. Remove desiccator from the condenser. => 875519 Removing and installing desiccator - section on "Removing"
2. Check the desiccator for wear/chips.
If there is wear/chips:
3. Remove the refrigerant line between the compressor and condenser. => 874319 Removing and installing compressor-condenser line - section on "Removing"
4. Replace the refrigerant line between the compressor and condenser.
5. Replace the condenser with desiccator. => 875019 Removing and installing condenser
6. Install the new refrigerant line between the compressor and condenser. => 874319 Removing and installing compressor-condenser line - section on "Installing"
7. => 873419 Removing and installing air conditioning compressor - section on "Installing"
If there is no wear/chips:
- Replace the desiccator. => 875519 Removing and installing desiccator
Subsequent work
1. Install drive belt. => 137819 Removing and installing drive belt - section on "Installing".
2. Install engine guard. => 108019 Removing and installing engine guard - section on "Installing".
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
3. Install left air cleaner housing. => 242519 Removing and installing air cleaner housing - section on "Installing"
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
4. Install left wheel housing liner. => 505619 Removing and installing front wheel housing liner - section on "Installing"
5. Fit front left wheel. => 440519 Removing and installing wheel - section on "Installing"
6. Fill refrigerant on the air conditioner in accordance with regulations. => 870317 Removing refrigerant by suction and filling
7. Open air outlet nozzles on the dashboard, and set fan to at least 75 %.
8. After allowing the system to stabilise at idle speed (approx. 5 sec.), switch on air conditioning and allow the engine to run uninterrupted for at least 2 minutes at an engine speed of less than => Engine speed: 1500 rpm.
9. Switch off the air conditioning again. Do not drive until the air conditioner has been filled.
Information
Only for vehicles with Porsche Dynamic Chassis Control (PDCC).
10. Park the vehicle in an open area and bleed Porsche Dynamic Chassis Control (PDCC). => 4303AW Safety requirements for Porsche Dynamic Chassis Control (PDCC)=> 430300 Bleeding Porsche Dynamic Chassis Control (PDCC)