A/C - No Cooling/Compressor Seized
Condition87 07 10
Aug. 23, 2007
2013314 Supersedes T.B. Group 87 number 07-08 dated July 26, 2007 Supersedes T.B. Group 87 number 07 03 dated Feb. 15, 2007 due to warranty table information change.
Air Conditioning Inoperative
Air conditioning does not cool, air conditioning compressor may seize.
Note:
Failure of compressor does not compromise driver visibility.
Vehicles with Zelex/Valeo air conditioning compressors only.
Tip:
Zelex/Valeo compressor can be recognized by the pulley (illustration 1).
Technical Background
Failure Mode Analysis:
There may be more than one concern with Zelex/Valeo air conditioning compressors that will render the air conditioning system inoperative:
1. The limiter (overload protection against seizing of the pulley), Part number 1K0820803 L and N, is broken or is missing (illustration 1, pos.1).
2. The compressor control valve, Part number 1K0820803 L and N, is restricted by metal particles and the compressor does not build up pressure.
Production Solution
Final production countermeasure pending.
Service
1: Limiter Broken
Limiter broken, compressor shaft/center bolt does not rotate manually with engine OFF. Center bolt can be loosened with a wrench (Illustration 1, call out number 2).
As a result the compressor Part No. 1K0820803 with index L and N is not driven.
No fault is logged in the fault memory.
The compressor must be replaced, the refrigerant system flushed and AC system recharged.
Note:
On all diesel engines a new Sanden compressor, Part No: 1K0820859 index "F" must be installed.
On the 2.0 L /147 kW gasoline engine a new Sanden compressor Part No: 1K0820859 index "F must be installed.
On all other gasoline engines see Parts Dept. for the latest compressor listings and parts information.
Flush the refrigerant system carefully following equipment instruction.
After flushing the refrigerant system install a new expansion valve and a new condenser.
Note:
After flushing the system the refrigerant oil quantity does not need adjusting. All oil has been removed from the system.
Procedure
1. Evacuate the refrigerant system with the AC service station, see Repair Manual Group 87, Refrigerant R134A Servicing in ElsaWeb, Working with the service station.
2. Flush complete AC circuit.
3. Install the air conditioning compressor with out compressor drive belt, see Repair Manual Group 87, Air Conditioner, A/C refrigerant system, servicing in ElsaWeb
Tip:
In this case the system oil quantity is not adjusted, the oil has been removed during the flushing process.
Note:
Replacement compressors come with a full system oil charge.
4. Turn the compressor 10 revolutions by hand, then install the compressor drive belt. (to avoid compressor damage, fluid surge), see Repair Manual Group 87, Ribbed belt pulley, removing and installing in ElsaWeb
5. Replace expansion valve and the condenser, see Repair Manual Group 87, A/C refrigerant system, servicing in ElsaWeb
6. Evacuate and recharge refrigerant system to the correct capacity with the AC service station, see Repair Manual Group 87, Refrigerant R134A Servicing, Working with the service station and Capacities in ElsaWeb.
Operate the A/C system, see Repair Manual Group 87, Refrigerant R134A Servicing, Working with the service station, A/C system, operating after charging in ElsaWeb.
2: Control valve of the compressor is blocked by metal particles.
The compressor does not build up pressure, no DTCs stored in fault memory.
Procedure
Note:
The control valve is in the compressor housing and cannot be serviced separately, the compressor must be replaced.
Tip:
As with service procedure 1 above, the refrigerant circuit must be flushed and the compressor, expansion valve and condenser must be replaced.
Note:
On all diesel engines a new Sanden compressor Part No. 1K0820859 index "F" must be installed following procedures in process 1.
On the 2.0 L /147 kW gasoline engine a new Sanden compressor Part No. 1K0820859 index "F" must be installed.
On all other gasoline engines see ETKA for the latest parts information.
Procedure
1. The compressor, expansion valve and condenser must be replaced, and the refrigerant system flushed, see 1: Limiter Broken procedure above.
Note:
When replacing the compressor observe the running-in instructions and adjusting compressor oil quantity in ElsaWeb.
Warranty
Required Parts and Tools
Tip:
Part number(s) are for reference only.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.