Compressor HVAC: Service and Repair

WARNING: Follow safety instructions for working on air-conditioning system. Service Precautions

NOTE:
- Read instructions on fast and slow leaks first. "General Repair Instruction." Service and Repair
- Use Special tools 5472, 5473 and 5474
- Always replace 0-rings in pipes and snap-on connections when replacing the compressor.





1. Disconnect battery negative cable
2. Drain system of refrigerant. Service and Repair
3. Remove air intake hose (M3).
- Remove hose connection to fan cover.
4. Remove control box air intake hoses (M4).
- Remove diagnostic units from control box.
- Remove control box air intake hoses.
- Disconnect inlet hose connection from fan cover (2 clips).
5. Remove fan cover (M5).
- Disconnect relays and cables from fan cover (2 tie strips).
- Remove fan cover (4 screws), remove relay shelf and spacers.
- Disconnect two-pin connector from fan relay and one-pin connector from fan motor.
- Remove fan cover.





6. Cover radiator with protector 5474 (M6).
7. Disconnect pipe connections on compressor (M7).
8. Disconnect snap-on connectors (M8).
- Disconnect snap-on connectors on receiver/dryer.

NOTE: Use snap-on connector tool 5472.

- Remove right-hand headlamp casing.
- Remove receiver/dryer bracket screw.
9. Remove air guide (2 T30 torx screws)(M9).
10. Remove receiver/dryer and bracket.
- With the bracket hooked onto the side member, lift the receiver/dryer out.
- Plug receiver/dryer pipe ends.





11. Disconnect drive belt, use 3/8" socket wrench (M11)
12. Remove compressor (M12).
- Disconnect compressor connector and temperature sensor.
- Disconnect the two screws on the compressor brackets.
- Lift compressor out.
- Switch brackets and pipe connection (flange) to the new compressor. Torque settings: brackets 40 Nm (30 ft.lb.), pipe connection 24 Nm (18 ft.lb.).

NOTE: Lubricate new O-rings between pipe connections and compressor end with compressor oil.

13. Check oil level on new compressor. "General Repair Instructions" Service and Repair
- Top up If necessary.

When replacing receiver/dryer:





14. Remove receiver/dryer from bracket.
- Switch hose to new receiver/dryer, torque setting 30 Nm (22 ft.lb.).

NOTE: Note hose position relative to receiver/dryer. Switch bracket. Use gauge 5473 to get right position.

Installation:
15. Install:
- Compressor.
- Compressor connector and temperature sensor.
- Drive belt.
- Receiver/dryer

NOTE: With snap-on connections, use new O-rings lubricated with compressor oil.

- Compressor pipe connections. Pipe connection torque settings: to compressor 60 Nm, from compressor 45 Nm (33 ft.lb.).

NOTE: Use New O-rings here too.

16. Fill system with refrigerant and test for leaks. Service and Repair
17. Remove shield 5474
18. Install:
- Air guide.
- Fan cover.
- Relays and cables to fan cover.
- Control unit box fresh air hoses and vent.
- Control unit box diagnostic unit.
- Air intake hose and vent.
- Battery negative cable.