Removal and Replacement

Removing And Installing The Compressor

Removal
1. Remove the cover above the heating/air-conditioning system.
2. Remove the refrigerant by suction using the service unit.
3. Disconnect the battery and cover the terminal or battery. Remove the complete air filter system.
4. Relieve the drive belt on the tensioning pulley and remove the belt.
5. Undo the B+ connection (2 nuts M6) on the engine and put it aside.
6. Remove the fluid of the power steering in the supply tank until below the connection. Remove the servo-tank (bayonet lock). Observe the marking (arrow) during installa-tion. Seal off the connection against dirt.







7. Undo compressor fastening screw between the intake pipes of cylinders 4 and 5.







8. Undo the front compressor fastening screws (2 each) and carefully pull the compressor out to the front. The rear fastening screw must be pulled out up to the refrigerant line.

NOTE: There is a spacer sleeve between the compressor and engine housing which remains on the engine housing. The screw must be pulled out to over the sleeve in order to remove the compressor.

9. Undo the refrigerant lines at the compressor. Immediately close connections and lines with plugs so that they are air-tight.







10. Disconnect electrical plug connection and carefully remove the compressor.


Installation

NOTE: New compressors are under pressure 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.

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 cb.cm of refrigerant oil out of the compressor and into a measuring glass. The remaining quantity of oil (approx. 120 cb.cm) remains in the compressor.

NOTE: 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).

4. Tightening torque for the compressor fastening screws on the engine (screws M8): 23 Nm (17 ftlb.)
5. Tightening torque for refrigerant line (screws M8 x 32): 23 Nm (17 ftlb.) Use fastening screws from the new compressor. Replace O-rings and wet the new rings with refrigerant oil.
6. Do not remove the plugs for the lines and compressor connection until shortly before installation.
7. Tightening torque for oil filler screw (M10 x 1): 26...36 Nm (19...25 ftlb.) Always replace the sealing ring.

Running-in regulations for new compressor

NOTE: Fill the air-conditioning system (fluid) via the high-pressure side from the refrigerant circuit with the engine "OFF".

1. If possible, all air outlet nozzles "OPEN", circulating air "CLOSED".
2. Start the engine and allow idle speed to stabilize (approx. 5 seconds).
3. Set the fan to max. output.
4. Switch on the air-conditioning system (AC switch) and allow it to run uninterrupted for at least 2 minutes at 1500 rpm.
5. After 2 minutes uninterrupted compressor operation time, the oil distribution in the air-conditioning system is completed and the compressor can be run up to the max. engine speed.