Remove/install refrigerant compressor

AR83.55-P-5300M

Remove/install refrigerant compressor

4.11.08

 

Remove/install

 Danger!

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.

AS83.00-Z-0001-01A



Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A



Protect air conditioning circuit and components from moisture when carrying out repair work

All models with air conditioning

AH83.30-N-0005-01A



Notes on handling R134a refrigerant

All models with R134a refrigerant

AH83.30-N-0003-01A

1

Drain air conditioning system (recycle refrigerant), evacuate, fill, inspect for leaks

 Add quantity of compressor oil evacuated to refrigeration circuit when charging air conditioning (new oil).

2.1

Remove lower engine compartment paneling

 Engine 112, 113 and 137

AR61.20-P-1105M

3

Slacken poly-V belt and remove

Engine 112, 113 in model 220

AR13.22-P-1202BA

Engines 613.960/ 961

AR13.22-P-1202HB

4.1

Remove fan shroud

 Engine 113, 137 only.

AR20.40-P-6800AB

5.1

Remove power steering pump

 Vehicles with Active Body Control (code 487) only.

AR46.30-P-0500N

5.2

Loosen power steering pump

 Model 220 with engine 613 only.

Remove the 3 mounting bolts; do not disconnect lines.

AR46.30-P-0500B

6

Disconnect refrigerant compressor (A9x1) plug-type connector

7

Remove bolts (1), remove suction line and pressure line and place to one side

 Plug openings (parts kit).

 Engine 112, 113, 137
Bolt, refrigerant lines to refrigerant compressor

*BA83.55-P-1002-01A

 Engine 613.960/961
Bolt, refrigerant lines to refrigerant compressor

*BA83.55-P-1003-01C

8.1

Remove bolts connecting front engine mount to front axle carrier

Engine 112 only.
Remove on both sides

Engine 112.922/944
Bolt, front engine mount to front axle carrier

*BA22.10-P-1001-01L

9.1

Lift engine (approx. 60 mm)

 Only Motor 112

AR01.10-P-7500-03I

10

Remove bolt (2)

Engine 112, 113, 137
Bolt, refrigerant compressor to bracket

*BA83.55-P-1001-01A

Engine 613.960/961
Bolt, refrigerant compressor to timing case cover

*BA83.55-P-1001-01C

Engine 613.960/961
Bolt, refrigerant compressor to bracket

*BA83.55-P-1002-01C

11

Remove refrigerant compressor (A9)

 Before installing a new refrigerant compressor, slowly allow pressure in refrigerant compressor to dissipate by loosening the pressure-side connector cover.

 Replace O-rings (moisten with compressor oil) if the AC compressor is not to be replaced.

12

Correct the oil level in the refrigerant compressor

AR83.55-P-5250E

 If the AC compressor has been replaced because of damage caused by an internal fault:

 Replace suction and pressure lines together with sealing rings

 Note oil filling quantity on replacement of the lines: 

*BF83.55-P-1006-01A

*BF83.55-P-1007-01A

Replace expansion valve

AR83.30-P-5520M

13

Replace fluid reservoir

AR83.30-P-6520M

14

Install in the reverse order

Number

Designation

Engine
112.922/944/972,
113.941/960,
137.970
in model 220

Engine
275.950/980
in model 220

BA22.10-P-1001-01L

Bolt, front engine mount to front axle carrier

Nm

35

35

Number

Designation

Engine
137
in model 215, 220

Engine
113 in model 215

Engine
113
in model 203, 209, 211, 219, 220

Engine
112
in model 220

BA83.55-P-1001-01A

Bolt, refrigerant compressor to bracket

Nm

20

20

20

20

BA83.55-P-1002-01A

Bolt, refrigerant lines to refrigerant compressor

Nm

20

20

20

20

Number

Designation

Engine 613.960/
961

BA83.55-P-1001-01C

Bolt, refrigerant compressor to timing case cover

Nm

20

BA83.55-P-1002-01C

Bolt, refrigerant compressor to bracket

Nm

20

BA83.55-P-1003-01C

Bolt, refrigerant lines to refrigerant compressor

Nm

20

Number

Designation

Refrigerant
compressor 7SE16
in Model 215

Refrigerant compressor
7SE16
in model 220

BF83.55-P-1006-01A

Additional oil filling capacity when replacing suction line

Compressor oil

cm3

20

20

Specifications for Operating Fluids

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

BF83.55-P-1007-01A

Additional oil filling capacity when replacing pressure line

Compressor oil

cm3

10

10

Specifications for Operating Fluids

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A