Remove/install refrigerant compressor

AR83.55-P-5300MM

Remove/install refrigerant compressor

15.11.11

28.2.07

Self-locking nut, steering joint to rack-and-pinion steering

*BA46.10-P-1002-01E

 

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 drained.

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

Slacken poly V-belt

 Replace if necessary.

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

3

Drain coolant

At radiator and crankcase

AR20.00-P-1142HB

4

Remove bottom section of soundproofing

5

Remove upper cooling-water hose

6

Remove fan shroud

AR20.40-P-6800MB

7

Unscrew bolt s(1) of front engine mounts (2) at front axle carrier



*BA22.10-P-1001-01D

8

Raise engine

 Ensure that rear of engine does not touch body and that no lines of cables are jammed in between when attaching to the engine lifting eyes.

Do not over-tension coolant lines.

Do not over-tension charge air hoses.

AR01.10-P-7500-03I

Engine support device, engine hoist
gotis://A_01_09.0

9

Disconnect plug connection on steering gear

10

Unscrew bolt of steering joint at lower steering shaft

Use new nut and bolt.



*BA46.10-P-1002-01E

11

Disconnect refrigerant line

AR83.55-P-5300-01MM

12

Prop front axle carrier with inspection pit or assembly lift

13

Lower front axle beam

 Remove only the 4 bolts at the axle beam.

Installation: Install new bolts.

AR33.10-P-0100I

14

Disconnect refrigerant compressor (A9x1) plug-type connector

15

Fit detachable body components for AC compressor (A9)

 Before installing a new AC compressor allow the pressure in the AC compressor to escape slowly by releasing the connector cap on the pressure side.

AR83.55-P-5300-03MM

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

16

Remove bolts (4), take out refrigerant compressor together with suction and pressure line

Bolt for refrigerant compressor to bracket.

*BA83.55-P-1001-01E

17

Remove bolts (3), remove suction and pressure lines from AC compressor and place to one side

 Plug openings (parts kit).

 Bolt, refrigerant line to AC compressor.

*BA83.55-P-1002-01E

18

Correct the oil level in the refrigerant compressor

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

 Replace suction and pressure lines with seals.

 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

19

Replace fluid reservoir

AR83.30-P-6520M

20

Install in the reverse order

Number

Designation

Engine
613.960
in model 220

Engine
628.960
in model 220

BA22.10-P-1001-01D

Bolt, front engine mount to front axle carrier

Nm

35

35

Number

Designation

Model
220.025/026/
028/063/065/
067/070/073/
074/075/125/
126/128/163/
165/167/170/
173/174/175/
176/178/179/
875/878

Model 220.083/084/087/
183/184/187

BA46.10-P-1002-01E

Safety screw and steering coupling locknut to rack-and-pinion steering

Nm

18

18

Number

Designation

Engine
628.960/
961

BA83.55-P-1001-01E

Bolt, refrigerant compressor to cylinder crankcase

Nm

20

BA83.55-P-1002-01E

Screw/bolt, refrigerant line to refrigerant compressor

Nm

20

Number

Designation

Refrigerant compressor
7SE16
in model 220

BF83.55-P-1006-01A

Additional oil filling quantity when replacing intake line

Compressor oil

cm3

20

Specifications for Operating Fluids

Sheet

BB00.40-P-0362-00A

BF83.55-P-1007-01A

Additional oil filling quantity when replacing pressure line

Compressor oil

cm3

10

Specifications for Operating Fluids

Sheet

BB00.40-P-0362-00A