Compressor HVAC: Service and Repair

Special tools: 999 5472, 999 5474, 999 5547


Special tools: 999 5596, 999 5598, 999 5599, 999 5600, 999 5602

TTTO1 Before starting work on the compressor or magnetic clutch compressor


WARNING! FOLLOW THE SAFETY PRECAUTIONS FOR WORK ON A/C SYSTEMS ACCORDING TO AC. SAFETY INSTRUCTIONS WHEN HANDLING REFRIGERANT Technician Safety Information

NOTE! Read the sections covering slow and quick leaks first, according to BG1. Service and Repair

NOTE! When replacing the compressor always install new O rings in pipes and quick-release connectors. Always plug pipes and couplings when working on the climate control system.


Removing compressor or magnetic clutch compressor







TTTO2 Removing compressor or magnetic clutch compressor, common operations
- First read TTTO1.
- Disconnect battery negative lead.
- When replacing the compressor on all engines and when replacing the magnetic clutch on turbocharged engines:
- Drain system of refrigerant according to BD.
- Remove fresh air intake hose to control module box.


TTTO3






- Remove suction intake hose and intermediate section between fan shroud nozzle and filter.


TTTO4






- For turbocharged engines:
- disconnect hose from charge air cooler (CAC) and bend out of the way
- remove cover over throttle pulley.


TTTO5






- On all engines except diesel engines:
- remove fan shroud
- cover radiator with protective panel 999 5474.


TTTO6
- Detach air receiver/dryer with bracket according to TTTN2 - TTTN7. Replacing Receiver/Drier or Suction Line
- Detach auxiliaries belt with adapter 999 5547
- Remove right front wheel.
- Raise car.
- Remove air baffle between spoiler and frame member.


TTTO7






- Loosen the compressor's rear mounting bolts.


TTTO8






- Partly detach the front right fender liner and push to one side.


TTTO9






- Loosen the compressor's front mounting bolts.


TTTO10






- Detach compressor and disconnect its connector (1).


TTTO11 Removing compressor after common operations completed






- Detach all pipe connections from the compressor.
- Remove receiver according to TTTN2 - TTTN7. Replacing Receiver/Drier or Suction Line
- Remove the compressor.


TTTO12 Removing magnetic clutch compressor after completing common operations






- Detach cable pipe from engine mounting and member.


TTTO13





- Detach lower hose for engine oil from radiator and plug hose and radiator.
- Detach cooling system and push forward.


TTTO14






- Locate compressor between sub-frame and radiator.


TTTO15






- Undo screw and drive plate using counter- hold 999 5596.


TTTO16






- Retain shims.



TTTO17






- Remove circlip.



TTTO18






- Pull off pulley using puller 999 5598 and socket 9995599.


NOTE! Location of tool on pulley.



TTTO19






- Disconnect magnetic coil connector and detach the magnetic coil diode (2 + 3).



TTTO20






- Remove magnetic coil.



Installing compressor or magnetic clutch compressor







TTTO21 Installing magnetic clutch compressor
- First read TTTO1.
- Install new magnetic coil. Tightening torque 5 Nm (3.7 ft.lb).


TTTO22






- Connect magnetic coil connector and reinstall the magnetic coil diode (2 + 3).


TTTO23







- Install new pulley using puller 999 5598 and socket 9995600.


NOTE! Location of tool behind the compressor mounting.


TTTO24






- Install circlip.


TTTO25






- Install shims.


TTTO26






- Install drive plate. Tighten using counter- hold 9995596. Tightening torque 13 Nm (9.6 ft.lb).


TTTO27 Checking clearance







- Check clearance between coupling plate and pulley using a feeler gauge:
- clearance should be between 0.3 and 0.5 mm (0.012 in and 0.020 in).
- 0.3 mm (0.012 in) clearance all the way round
- 0.6 mm (0.024 in) should not go in anywhere

- If clearance is not within the stated values; Replace shims. The following dimensions are available:
- 0.2 mm (0.008 in)
- 0.3 mm (0.012 in)
- 1.0 mm (0.039 in)


TTTO28 Installing, common operations
- First read TTTO1.
- Install compressor, tightening torques 40 Nm (30 ft.lb).
- When replacing the compressor on all engines and when replacing the magnetic clutch compressor engine T52521:
- locate receiver
- Install connecting hoses, tightening torque 25 ± 6 Nm (19 ± 4 ft.lb).


NOTE! Use new O-rings lubricated with compressor oil.


- Install air baffle between spoiler and frame member.
- Lower car.
- Remove protective panel 999 5474.
- When replacing the compressor on all engines and when replacing the magnetic clutch compressor engine T52521:
- Install receiver with bracket according to TTTN8 - TTTN1O. Replacing Receiver/Drier or Suction Line

- Install auxiliaries belt.
- Install fan shroud
- Install suction intake hose and intermediate section between fan shroud nozzle and filter.

- For turbocharged engines:
- disconnect hose from charge air cooler (CAC) and bend out of the way
- remove cover over throttle pulley.
- Reinstall fresh air intake to control module box.
- Reinstall battery lead.


NOTE! When replacing the compressor on all engines and when replacing the magnetic clutch compressor engine T52521: Fill system with refrigerant according to BD. and BF. Service and Repair