Refrigerant Lines, Disconnecting From Compressor and Connecting

Refrigerant Lines, Disconnecting from Compressor and Connecting

• Compressor is always driven when engine is running; there is no magnetic clutch. Engine is therefore not to be started unless refrigerant circuit has been properly assembled. For example; if the refrigerant lines are not connected to A/C compressor, when the engine is running the A/C compressor may heat up (via internal heat generation) so much that the A/C compressor will be damaged. Such internal heat generation results from the fact that - even with delivery near 0% - the compressor is confronted with a fixed resistance (sealed circuit).

Removing

- Discharge refrigerant circuit.

- Drain the coolant.

- Remove the bolts - arrows -.





- Lay the coolant thermostat housing aside with the coolant hoses - 1 and 2 - connected.

CAUTION!
Risk of damaging refrigerant lines and hoses.

• Do not stretch, kink or bend refrigerant lines and hoses.

- Remove the screw - 2 -, remove the refrigerant line from the A/C compressor and move it upward.





- Remove the screw - 1 - and disconnect the refrigerant line from the A/C compressor.

• The illustration shows the engine removed.

- Close all open lines and connections on A/C compressor with suitable caps (avoid dirt and moisture from entering the system).

Installing

Installation is done is reverse order, observe the following:

- Replace O-ring seals - D - and - E -.





- Check the guide ring - F - on the connections for both refrigerant lines - B - and - C - for damage.

- Insert the respective O-ring seal - D - and - E - in the groove - G - on the connections for both refrigerant lines - B - and - C -.

• The O-rings from the connection caps, which were delivered with the replacement A/C compressor, may not be used again.

• Coat the O-ring with refrigerant oil before installing. Refer to => [ Refrigerant Circuit O-Rings ] Refrigerant Circuit O-Rings.

• Make sure the O-ring seals are seated properly in the groove - G - on the respective refrigerant line.

• Following attachment of refrigerant pipes to compressor (and installation of compressor) check routing of pipes. They must be inserted in holders provided and not make contact with other components.

- Insert both refrigerant lines in the respective connection on the A/C compressor.





- Tighten the bolts - 1 and 2 -.

• Tightening specification: 25 Nm.

- Evacuate and fill refrigerant circuit.

- Install the thermostat housing.

- Fill with coolant.

After finishing the repairs, perform the following work on the Climatronic Control Module (J255) using the Vehicle diagnosis, testing and information system VAS 5051/ in the "Guided Fault Finding" function:

- Check the DTC memory and erase any malfunctions shown.

- Operate the A/C system after filling the refrigerant circuit, refer to => [ Operating After Filling Refrigerant Circuit ] Heating, Ventilation & Air Conditioning.

• Note the information regarding operating the A/C system after filling.