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Removing and installing air conditioner compressor
Removing and installing air conditioner compressor
Special tools and workshop equipment required
   
t  Torque wrench -V.A.G 1331/- (5…50 Nm)
  W00-0427
t  Air conditioner service station -VAS 6007A- or later model.
  Note
t  The refrigerant circuit must be purged with refrigerant R134a under the following circumstances:
t  If dirt or other contamination is in the circuit.
t  If during the evacuation of a leak-tight refrigerant circuit the vacuum is not maintained at the gauge (there is moisture in the refrigerant circuit and this generates vapour pressure).
t  If the refrigerant circuit has been left open for longer than normally required for repairs (e.g. following an accident).
t  When pressure and temperature measurements in the refrigerant circuit indicate that there is moisture in the refrigerant circuit.
t  There is doubt about the amount of refrigerant oil in the refrigerant circuit.
t  The air conditioner compressor has to be exchanged because of internal damage (e.g. noisy or lack of power).
The procedure for purging with refrigerant R134a is described in ELSA under → Air conditioning system with refrigerant R134a; Rep. gr.00.
Notes on repair work to vehicles with air conditioning system and on handling refrigerant can be found in ELSA under → Air conditioning system with refrigerant R134a ; Rep. gr.00.
Notes on testers and tools for repair work to vehicles with air conditioning can be found in ELSA under → Air conditioning system with refrigerant R134a; Rep. gr.00.
Comply with notes → Anchor.
Removing
–  Remove poly V-belt → Rep. gr.13.
–  Disconnect connector -2- from air conditioner compressor -1-.
  W00-10176
–  Extract refrigerant, e.g. with air conditioner service station -VAS 6007A- before opening refrigerant circuit.
  WARNING
Danger from refrigerant escaping under pressure!
Freezing of skin and other body parts.
l  Evacuate the refrigerant and then open the refrigerant circuit immediately.
l  If more than 10 minutes have elapsed since evacuation and the coolant circuit has not been opened, evacuate the refrigerant again. Pressure builds up in the coolant circuit as a result of secondary evaporation.
–  Unscrew bolts -4- and disconnect refrigerant lines -3- and -6- from air conditioner compressor -1-.
  Note
The upper bolt -4- of refrigerant lines -3- can be accessed through the maintenance opening in the lock carrier.
–  Remove securing bolts -5- and remove air conditioner compressor.
Installing
  Note
t  Ensure that centring sleeves -6- are properly seated.
t  Install in reverse order, noting the following:
t  Observe remarks on installation of air conditioner compressor → Anchor.
  N87-10893
t  If a new air conditioner compressor is installed, a „compressor run-in“ must be carried out → Anchor.
Notes on installing air conditioner compressor
–  Only start engine after refrigerant circuit has been assembled.
–  After installing a new air conditioner compressor or filling with fresh refrigeration oil (e.g. after purging refrigerant circuit), turn air conditioner compressor poly V-belt pulley 10 revolutions by hand before starting engine. This will prevent damage to the air conditioner compressor.
–  If possible, only start engine when refrigerant circuit is full.
  Note
t  The air conditioner compressor is driven by the air conditioning system magnetic clutch -N25-.
t  The air conditioning system magnetic clutch -N25- only starts if it receives a signal from the high-pressure sender -G65- to avoid damage to the compressor when refrigerant circuit is empty.
  Note
Note the following when starting engine for first time after filling refrigerant circuit:
–  Start engine with air conditioner compressor switched off (control lamp in AC button is off) and wait until idling speed is stable.
–  Open dash panel vents.
–  Fresh air blower -V2- at least set to 3.
–  Set temperature to „Cold“ on control and display unit for air conditioning system.
–  Switch on air conditioner compressor (control lamp in AC button lights up) and let it run for at least 5 minutes with engine at idling speed.
Air conditioner compressor run-in
  Note
If a new air conditioner compressor is installed, a „compressor run-in“ must be carried out → Anchor.
The following conditions must first be met:
l  Compressor filled with refrigerant filled at pressure end
l  Engine off
l  Vents set to „OPEN“.
l  Blower to „3“
l  Air conditioning system off (warning lamp in AC button off)
–  Start engine.
–  Wait approx. 5 seconds until idling has stabilised.
–  Switch on air conditioning system (warning lamp in AC button on).
–  Allow engine to idle for 2 minutes.
–  Switch engine off.
  N87-10892

Removing and installing magnetic clutch > < Assembly overview - belt pulley