Compressor HVAC: Service and Repair

AR83.55-P-5300M Remove/Install Refrigerant Compressor







DANGER:
- Risk of explosion from welding or soldering work on closed air conditioning system. Risk of poisoning from inhaling overheated refrigerant vapors. Risk of injury from skin and eye contact with liquid refrigerant.
- Do not carry out any welding work on the closed air conditioning system or in the surrounding area. No smoking or naked flames. Wear eye protection and protective gloves. Work only in well ventilated areas. Do not carry out repair work on the circuit of the air conditioning system unless the system is drained.

CAUTION: Protect air conditioning circuit and components from moisture when carrying out repair work

1 Drain air conditioning system (recycling), evacuate, fill, inspect for leaks

CAUTION: When filling the air conditioning system, feed extracted quantity of compressor oil back into the refrigerant circuit (new oil).

2 Remove lower engine compartment lining

NOTE: Engine 112, 113 and 137 only.

3 Slacken ribbed V-belt and take off
4 Remove fan shroud

NOTE: Engine 113, 137 only.

5.1 Remove steering pump

NOTE: Vehicles with Active Body Control (Code 487) only.

5.2 Undo power steering pump

NOTE: Model 220 with engine 613 only.

- Unscrew the 3 fastening screws, do not disconnect lines.

6 Disconnect refrigerant compressor (A9x1) plug-type connector
7 Unscrew screws (1), remove intake and pressure line, and lay to one side

CAUTION: Plug openings (parts kit).

- Refrigerant line screw to refrigerant compressor: 20 N.m

8 Unscrew screws (2)
- Adjust double box-type wrench for lower front screw

- Refrigerant compressor screw to bracket: 20 N.m
- Refrigerant compressor screw to timing case cover: 20 N.m

9 Remove refrigerant compressor (A9)

NOTE: Before installing a new refrigerant compressor, slowly allow pressure in refrigerant compressor to dissipate by loosening the pressure-side connection cover.

CAUTION: Replace O-rings (coat with compressor oil) if the refrigerant compressor is not replaced.

10 Correct the oil level in the refrigerant compressor

CAUTION: If the refrigerant compressor has been replaced as a result of internal damage, Replace intake and pressure lines with seal rings.

NOTE:
Note oil filling quantity on replacement of the lines.
- Replace expansion valve.

- Additional oil filling quantity on replacement of intake line: 20 cu.cm
- Additional oil filling quantity on replacement of pressure line: 10 cu.cm

11 Replace receiver/drier
12 Install in the reverse order.