8.1.01.1 Compressor Removal/Renewal

8.1.01.1 Compressor Removal/Renewal

Procedure

1. Open the bonnet and fit a wing cover.
2. Depressurise the air conditioning system.
3. Disconnect the low and high pressure hoses from the rear of the compressor. Plug the hose ends to prevent the ingress of dirt.
4. Remove the compressor pivot bolt securing nut.
5. Carefully separate the muffler from the compressor and remove and discard the ‘O’ ring seal.
6. Fit a blanking plug to the muffler and a blanking plate to the compressor, fit and tighten the bolt that secures blanking plate.
7. Raise the vehicle to working height on a ramp.

10. Slacken the compressor drive belt adjuster rod and adjuster plate securing nuts and bolts (Fig. 1-4, 5, 6 and 7).
11. Slacken adjuster nut (Fig. 1-10).
12. Remove the nut and bolt (Fig. 1-4 and 5) from adjuster plate (Fig. 1-3).
13. Slacken trunnion nut and bolt (Fig. 1-9 and 2) and remove the adjuster rod (Fig. 1-1).
14. Disconnect the compressor multi-plug.
15. Remove the compressor drive belt.

16. Pivot the compressor away from engine, support the compressor and remove the top pivot bolt and lift the compressor clear of the vehicle.
17. Remove the mounting brackets from the compressor.
18. Lift the compressor up to the engine and fit the top pivot bolt (Fig. 1-2) from above.
19. Attach adjustment rod loosely to the compressor (Fig. 1-1) with nut and bolt (Fig. 1-6 and 7).
20. Loosely attach adjustment plate (Fig. 1-3) to the compressor with nut and bolt (Fig. 1-4 and 5).
21. Fit bolt (Fig. 1-2) through trunnion (Fig. 1-8) and fit nut (Fig. 1-9) to the bolt.
22. Fit the drive belt over the pulley, move the compressor away from the engine to tension the drive belt and lightly tighten the bolts and nuts.
23. To obtain the correct tension on the drive belt tighten adjuster nuts (Fig. 1-10). The belt is correctly tensioned when a load of 59-63.6 kg (130-140 lb) applied at the centre deflects the belt 4 mm.
24. Ensure that all securing bolts and nuts are fully tightened.
25. Lower the vehicle to the ground.
26. Remove the blanking plate and the blanking plugs from the compressor.
27. Fit new ‘O’ ring seals to the low and high pressure hoses and connect them to the compressor. Fit the retaining plate, fit and tighten the screw.
28. Charge the air conditioning system.
29. Remove the wing cover and close the bonnet.