A/C System Seal Removal

WARNING: Before commencing work, read and observe Safety precautions when working on A/C systems". Technician Safety Information

CAUTION:
- If replacing the compressor, the new unit with the new connection fittings and seals must be used.

- Also read "General information on repair and replacement of A/C system components". Vehicle Damage Warnings

Modification Of Earlier Cars For New Type Of Seals - Compressor Removal
1. Drain A/C system of refrigerant. Refer to the Drainage and Recycling, Checking A/C. Service and Repair
2. Disconnect battery ground lead.





3. Remove grille and cover panel.





4. Remove/disconnect:
- Air baffles.
- Bolts securing condenser to radiator.
- Air cleaner intake.
- Pressostat connectors.
- Ambient air sensor (1).





5. Remove:
- Splashguard under radiator.
- Engine cover.





6. Undo condenser couplings (3).





7. Remove/disconnect:
- Pipe clip retaining screw (1).
- Hoses from bracket (2).
8. Clean connections internally. Seal all open ends, for example with butyl tape, part number 3540085-2.





9. Apply masking tape to protect chromed section of bumper. Remove condenser by lifting carefully straight up.





10. Remove:
- Generator lower support bolt (slacken upper bolt).
- Drive belt.
- Compressor front mounting bolts (two). Rear mounting bolts are removed later.





11. Remove/disconnect:
- Pipe retaining clips
- Air receiver, evaporator and compressor (see illustration).
- Apply hose clamp to expansion tank hose. Disconnect hose.

CAUTION: Remember to seal open ends.

NOTE: It is extremely important that the following procedure for removing the compressor be followed exactly, otherwise problems may be encountered when lowering the unit.





12. Remove/disconnect:
- Hose bracket under compressor.
- Electromagnetic clutch connector (green lead) (1).
13. Unscrew both rear mounting bolts until heads are bearing against plate at rear. Wedge upper bolt in position with screwdriver if bolt is difficult to hold against plate.

NOTE: Rear bolts cannot be removed.

14. Move compressor bracket forward/upward against shoulder on mounting bracket, tilt unit towards right and lift clear.