Compressor HVAC: Service and Repair
Removing and installing the compressor
Removal
1. Remove the cover above the heating/air-conditioning system.
2. Remove refrigerant by suction using the service unit.
3. Remove the left seat.
Disconnect the battery and cover the terminal or battery. Remove the lid for the engine compartment and rear wall flap behind the seats.
4. Relieve the drive belt on the tensioning pulley and remove the belt.
5. Detach the battery positive connector at the B+ connection on the engine. Undo the B+ connection (2 screws 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 installation. Seal off the connection against dirt
7. Undo the compressor fastening screw between the intake pipes, cylinders 4 and 5.
8. Undo the refrigerant lines at the compressor. Immediately close the connections and lines with plugs so that they are air-tight.
9. Undo the front compressor fastening screws (2 ea.) and disconnect the electrical plug connection.
10. Carefully remove the compressor to the front.
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 cubic cm of refrigerant oil out of the compressor and into a measuring glass. The remaining quantity of oil (approx. 120 cubic 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 ft lb.)
5. Tightening torque for refrigerant line (screws M8 x 32): 23 Nm (17 ft lb.)
Use fastening screws from the new compressor. Replace O-rings and wet 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 - 27 ft lb.)
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.