A/C Compressor with Drive Unit, Engine Code BAR
A/C Compressor with Drive Unit, Engine Code BAR
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Adapter (10-222 A/22)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• A toothed gear and a driveshaft - B - drive the compressor.
• On vehicles with an 8 cylinder engine, the refrigerant circuit must be drained to remove the A/C compressor.
• A/C Compressor Bracket, Removing and Installing.
- Drain the refrigerant circuit.
- Remove the left and right air filter housing. Refer to=> Engine Mechanical, Fuel Injection and Ignition 24 Removal and Installation.
- Remove left front wheel.
- Remove noise insulation if necessary. Refer to
- Discharge coolant circuit.
- Remove the front and rear engine cover.
- Remove nuts and bolts - arrows - of retaining clamps for refrigerant line.
• Bolts of retaining clamps for refrigerant line are removed so that the refrigerant lines can be pushed aside slightly and not damaged when inserting engine support bridge.
Preparatory work to remove left engine support:
• This repair manual only outlines the procedure for removing the left engine support. Always use the corresponding repair manual for removing the left engine support.
- Position Engine Support Bridge (10-222 A) with Adapters (10-222 A/22) and Connectors (T40091/3) on to bolted flanges of fender.
- Assemble the other components of the Engine Support Bridge (10-222 A) as shown in the illustration. To do so, position the Supports (10-222 A/19) on the longitudinal member seams be careful of the refrigerant lines on the longitudinal member when doing this.
- Hang the hooks of the short Spindle (10-222 A/10) into the left rear engine lifting eye.
- Slide the Support (T40091/2) using Slider (T40093/5) into both Connectors (T40093/4).
- Assemble the long spindle from Engine Support Sling (10-222 A) and hang the hook of the spindle into the left front engine lifting eye.
CAUTION!
Secure Support (T40091/2) using stud and cotter pins of Connector (T40093/4).
- Pre-tension the engine by uniformly tightening both spindles.
- Disconnect coolant hose - hoses -.
- Remove the nuts and bolts - 1 - through - 5 - and the left engine support "Engine Mechanical".
- Disconnect the connectors to the Refrigerant Temperature Sensor (G454) - 1 -.
- Disconnect both refrigerant lines - 2 - and - 3 - from the A/C compressor.
• Seal open pipes and connections at condenser with suitable caps to prevent dirt and moisture from entering.
• Do not bend, kink or stretch lines or hoses as refrigerant lines and refrigerant hoses may be damaged.
- Hold the A/C compressor driveshaft - A - in place using an open-end wrench and turn compressor drive unit - B - in the direction of the arrow - C -.
• Do not turn the driveshaft - A -.
• Driveshaft - A - can be slid into drive wheel through the boot - E - after loosening threaded connection.
- Mark the 2-pin connector - 1 - to the A/C Compressor Regulator Valve (N280) so it does not get switched with the connector to the engine mount.
- Disconnect the 2-pin connector - 1 - to the A/C Compressor Regulator Valve (N280).
- Remove three bolts - arrows - tightening torque 25 Nm.
- Remove the A/C compressor forward.
- Remove the bushings - F - from the compressor if necessary.
Installing
• There is a quantity of refrigerant oil in the removed A/C compressor. Follow the information on replacing the A/C compressor.
- Remove the bushings - C - from the A/C compressor bracket if necessary.
- Thoroughly clean the contact surfaces - A - and - B - on the bracket and the contact surfaces on the A/C compressor.
- Install the bushings - C - in the compressor bracket.
• Make sure the bushings - C - are seated correctly and the contact surfaces are clean. Bushings that are installed incorrectly and dirty or damaged contact surfaces can lead to alignment irregularities between the compressor and engine. Alignment irregularities over time lead to damage to the input shaft or compressor.
- If necessary, install the A/C compressor driveshaft - A - in the engine drive wheel and check the seating of it and the boot - E -.
• A clamp on the engine toothed drive gear flange - C - prevents the boot - E - from slipping.
- Check the A/C compressor and refrigerant line connections for damage or dirt.
- Install the A/C compressor with the bolts - D - and washers - E - on the bracket (bolt - D - tightening specification: 25 Nm). Be careful of the bushings - F -.
- Install the refrigerant lines on the A/C compressor with new, lightly oiled o-ring seals (bolt - A - tightening specification: 20 ± 3 Nm).
• Dimensions of O-ring seals - B - and - C - => Parts Catalog.
- Before installing the driveshaft, rotate the A/C compressor by hand after installing it 10 turns in the direction of the arrow - C - using the compressor drive unit - B -. This will prevent the compressor from being damaged the first time it is switched on.
• Refrigerant oil can collect in the compressor compression chamber after removing the compressor or adding new oil for example, by blowing through the refrigerant circuit. Rotating forces the refrigerant oil out of the compression chamber.
- Tighten the driveshaft, hold the compressor driveshaft - A - in place using an open-end wrench and turn the compressor drive unit - B - in the direction of the arrow - D - (tightening specification 60 Nm).
• Do not turn the driveshaft - A -.
• After installing the driveshaft - A -, check the boot - E - installation position.
- Re-install remaining components removed.
• Follow the tightening specifications for the bolts and nuts that have been removed.
- Fill the coolant and bleed the refrigerant circuit.
- Empty and fill the refrigerant circuit. Refer to"Refrigerant R134a - Servicing"
- Check the DTC memory in the Climatronic Control Module (J255) and erase any faults shown if necessary. => Vehicle Diagnosis, Testing and Information System VAS 5051 in the "Guided Fault Finding" function
- Follow the information about starting the A/C system after installing the A/C compressor.