Removal and Replacement
Replacing the compressor or the magnetic clutch for the compressor
Preparations
Before starting work on the compressor or magnetic clutch compressor
Warning! Follow the safety instructions for work on air conditioning systems. See Refrigerant, safety regulations Refrigerant, Safety Regulations
Note! First read the instructions covering slow and fast leaks. See Oil in the A/C system Oil in the A/C system
Note! When replacing a compressor, always replace the O-rings in pipes and quick-release connectors.
Note! Always plug the pipes and couplings when working on the climate control system.
Removing the compressor or the magnetic clutch for the compressor
Removing the compressor or magnetic clutch, common operations
First read Before starting work on the compressor or magnetic clutch compressor.
Disconnect the battery negative lead.
When replacing the compressor on all engines and when replacing the magnetic clutch on turbocharged engines, drain the refrigerant from the system. See Emptying/vacuum pumping/filling with refrigerant Emptying/Vacuum Pumping/Filling With Refrigerant
Remove the fresh air intake hose from the control module box.
Remove the intake hose and intermediate piece between the fan shroud nozzle and filter.
Turbocharged engines
Disconnect the hose from the charge air cooler (CAC). Push the hose to one side.
Remove the cover over the throttle pulley.
For all engines except diesel
Remove the fan shroud.
Cover the radiator with protective plate 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection
Remove the receiver and drier including the bracket. See Replacing receiver / drier or suction pipe Removal and Replacement
Remove the auxiliaries belt. Use adapter 999 5547 ADAPTOR 999 5547 Adapter.
Remove the right front wheel.
Raise the car.
Remove the air baffle between the spoiler and the frame member.
Slacken off the rear mounting screws on the compressor.
Remove the front right fender liner partially. Push the fender liner to one side.
Slacken off the front mounting screws on the compressor.
Remove the compressor. Disconnect the connector (1).
Removing the compressor, (after common operations)
Disconnect all pipe couplings from the compressor.
Remove the receiver according to Replacing receiver / drier or suction pipe Removal and Replacement
Remove the compressor.
Removing the magnetic clutch from the compressor, (after common operations)
Remove the cable conduits from the engine mountings and members.
Disconnect the lower hose for the engine oil from the radiator. Plug the hose and radiator.
Disconnect the air conditioning aggregate and slide it forwards.
Position the compressor between the sub-frame and radiator.
Slacken off the screw and the clutch plate. Use counterhold 999 5596 Counterhold 999 5596 Counterhold.
Retain the shims.
Remove the snap ring.
Note! Location of the tool on the pulley.
Pull off the pulley. Use puller 999 5598 Puller 999 5598 Puller and socket 999 5599 Socket with ring 999 5599 Socket With Ring.
Disconnect the solenoid coil connector. Remove the solenoid coil diode (2+3).
Remove the solenoid coil.
Installing the compressor or magnetic clutch
Installing the magnetic clutch for the compressor
First read Before starting work on the compressor or magnetic clutch compressor.
Install a new magnet coil. Tighten to 5 Nm .
Connect the solenoid coil connector. Install the solenoid coil diode (2+3).
Note! Location of the tool behind the compressor mounting.
Install a new pulley. Use puller 999 5598 Puller 999 5598 Puller and socket 999 5600 Socket with ring 999 5600 Socket With Ring.
Install the snap ring.
Install the shims.
Install the clutch plate. Tighten using counterhold 999 5596 Counterhold 999 5596 Counterhold. Tighten to 13 Nm .
Checking the clearance
Check the clearance between the clutch plate and pulley. Use a feeler gauge. The clearance should be 0.3-0.5 mm. The clearance must be at least 0.3 mm but must not exceed 0.6 mm.
If the clearance is not within the stated values: Replace the shims. The following dimensions are available: 0.2 mm, 0.3 mm and 1.0 mm.
Installing (common operations)
Note! Use new O-rings lubricated with compressor oil.
Note! When replacing the compressor on all engines and when replacing the magnetic clutch on T5252I engines, fill the system with refrigerant according to BD. Draining/vacuum pumping/filling with coolant and leak-finding Draining/Vacuum Pumping/Filling with Coolant and Leak-Finding.
First read Before starting work on the compressor or magnetic clutch compressor.
Install the compressor. Tighten to 40 Nm .
When replacing the compressor on all engines and the magnetic clutch on T5252I engines:
Position the receiver.
Install the hoses. Tighten to 25± 6 Nm .
Install the air baffle between the spoiler and frame member.
Lower the car.
Remove protective plate 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection.
When replacing the compressor on all engines and the magnetic clutch on T52521 engines:
Install the receiver and bracket.
Install the auxiliaries belt.
Install the fan shroud.
Install the intake hose and the intermediate piece between the fan shroud nozzle and filter.
Turbocharged engines:
Disconnect the hose from the charge air cooler (CAC). Push the hose to one side.
Remove the cover over the throttle pulley.
Install the fresh air intake hose on the control module box.
Connect the battery lead.