Removal and Installation

Removal and Installation

Removal
1. Open the bonnet and disconnect the battery earth lead.
2. Depressurize the air conditioning system.





3. Remove the bolt securing the muffler plate (1).Tighten to 32-37 Nm (23.6-27.2 ft lb). Remove the muffler securing bolt (2). Tighten to 40-50 Nm (29.5-36.8 ft lb). Remove the "0" ring seals and discard.
4. Fit protective caps to the disconnected hoses and a protection plate to the compressor.
5. Release the distributor cap retaining clips and displace the cap with the HT leads over the engine.





6. Loosen the compressor drive belt trunnion securing bolt (1) and the adjusting rod pivot bolt (2). From below loosen the compressor front (3) and rear pivot bolts (3).
7. From above, adjust the compressor towards the engine until the drive belt can be removed.
8. Remove the drive belt trunnion securing nut and bolt (1).
9. Disconnect the compressor clutch multi-plug connector (4).





10. Disconnect the superheat switch cable (4).
11. Remove the bolts securing the exhaust heat shield and remove the shield.
12. Remove the compressor rear pivot bolt and spacers (3).





13. Remove the compressor front pivot bolt (3).
14. Carefully remove the compressor with the rear end upwards to prevent oil loss.
15. Remove the bolts securing the support brackets and remove the brackets.
16. Remove the bolt securing the adjuster rod and remove the rod.

Installation

NOTE: Installation is the reverse of the removal procedure, observing the following points:
- Do not fully tighten the securing bolts until the drive belt is adjusted to the correct belt tension of 3.3 kg to give a deflection of 4.4 mm when pressure is applied at the mid-point of the belt.
- Ensure that all the nuts and bolts are fully tightened when the belt has been correctly adjusted.
- Ensure new "0" ring seals are fitted and the protective caps are not removed until the last possible moment before connecting the hoses.
- Ensure all hose union nuts are tightened to the correct torque.
- Fit a new receiver/dryer, evacuate and recharge the system.