Remove/install refrigerant compressor

AR83.55-P-5300GL

Remove/install refrigerant compressor

14.02.2019

Engine

612.965 in model 463.322/323

with code H02 (Air conditioning, manual)

Engine

612.966 in model 461.302/332/342/345

with code H02 (Air conditioning, manual)

Engine

642.884 in model 461.305/333/340/343

with code H02 (Air conditioning, manual)

Engine

642.975 in model 461.304/334/344/346

with code H02 (Air conditioning, manual)

Modification notes

23.01.2019

Remove engine charge air duct from exhaust gas turbocharger, added.

Operation step 6

Shown on model 461.302

1

Screw

2

Suction pipe

3

Screw

4

Pressure line

5

Bolts

A9

Refrigerant compressor

A9x1

Refrigerant compressor connector

 Warning

Risk of poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

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 rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

Notes on coolant level

AH20.00-P-1142-01CW

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

 

Remove/install

1

Remove refrigerant reservoir.

AR83.30-P-6520GM

 Replace fluid reservoir each time refrigerant circuit is opened.

2

Remove radiator.

Model 463.322/323 with engine 612.965
with code H02 (Air conditioning, manual)
with code H12 (Auxiliary heater)

AR20.20-P-3865GT

3

Remove heater.

Model 461.304/334/344/346 with engine 642.975
with code H02 (Air conditioning, manual)
with code H12 (Auxiliary heater)
Model 461.305/333/340/343 with engine 642.884
with code H02 (Air conditioning, manual)
with code H12 (Auxiliary heater)

AR83.70-P-5302GX

Model 461.302/332/342/345 with engine 612.966
with code H02 (Air conditioning, manual)
with code H12 (Auxiliary heater)
Model 463.322/323 with engine 612.965
with code H02 (Air conditioning, manual)
with code H12 (Auxiliary heater)

AR83.70-P-5302GL

4

Remove poly-V-belt.

Model 461.302/332/342/345 with engine 612.966
with code H02 (Air conditioning, manual)
Model 463.322/323 with engine 612.965
with code H02 (Air conditioning, manual)

AR13.22-P-1202HB

Model 461.304/334/344/346 with engine 642.975
with code H02 (Air conditioning, manual)
Model 461.305/333/340/343 with engine 642.884
with code H02 (Air conditioning, manual)

AR13.22-P-1202GY

5

Remove left charge air hose.

Model 461.302/332/342/345 with engine 612.966
with code H02 (Air conditioning, manual)
Model 461.304/334/344/346 with engine 642.975
with code H02 (Air conditioning, manual)
Model 463.322/323 with engine 612.965
with code H02 (Air conditioning, manual)

6

Remove engine charge air duct from exhaust gas turbocharger.

Model 461.305/333/340/343 with engine 642.884
with code H02 (Air conditioning, manual)

AR09.41-P-8622GX

7

Release and disconnect refrigerant compressor connector (A9x1).

8

Remove suction line (2) from refrigerant compressor (A9) and seal openings with suitable stop plugs.



Compressor oils (specification 362.3)

BB00.40-P-0362-03A

 Installation: Install new seals and wet with compressor oil.

 Suction line to refrigerant compressor

*BA83.30-P-1006-01C

 Record plug

*129589009100

9

Remove pressure line (4) from refrigerant compressor (A9) and seal openings with suitable stop plugs.



Compressor oils (specification 362.3)

BB00.40-P-0362-03A

 Install new seals and wet with compressor oil.

 Pressure line at A/C compressor

*BA83.30-P-1007-01C

 Record plug

*129589009100

10

Remove bolts (5).

 Model 461.302/332/342/345 with engine 612.966
with code H02 (Air conditioning, manual)
Model 463.322/323 with engine 612.965
with code H02 (Air conditioning, manual)Screw, refrigerant compressor to timing case cover

*BA83.55-P-1001-01C

 Model 461.302/332/342/345 with engine 612.966
with code H02 (Air conditioning, manual)
Model 463.322/323 with engine 612.965
with code H02 (Air conditioning, manual)Screw, refrigerant compressor to bracket

*BA83.55-P-1002-01C

 Model 461.304/334/344/346 with engine 642.975
with code H02 (Air conditioning, manual)
Model 461.305/333/340/343 with engine 642.884
with code H02 (Air conditioning, manual)Bolt, refrigerant compressor to timing case and left engine support

*BA83.55-P-1001-01TU

 Model 461.304/334/344/346 with engine 642.975
with code H02 (Air conditioning, manual)
Model 461.305/333/340/343 with engine 642.884
with code H02 (Air conditioning, manual)Bolt, refrigerant compressor to bracket

*BA83.55-P-1002-01TU

11

Remove the A/C compressor(A9).

12

Install in the reverse order.

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

13

Perform engine test run and check air conditioning system for proper operation.

 Air conditioning

Number

Designation

Model 461

Model 463
up to model year 2019

BA83.30-P-1006-01C

Suction line to refrigerant compressor

Nm

20

20

 Air conditioning

Number

Designation

Model 463
as of model year 2019

BA83.30-P-1006-01C

Suction line to refrigerant compressor

Nm

20

 Air conditioning

Number

Designation

Model 461

Model 463
up to model year 2019

BA83.30-P-1007-01C

Pressure line at A/C compressor

Nm

20

20

 Air conditioning

Number

Designation

Model 463
as of model year 2019

BA83.30-P-1007-01C

Pressure line at A/C compressor

Nm

20

 Refrigerant compressor

Number

Designation

Engine 611.960/961/962, 612.961/962/963/965/966/967/990, 613.960/961

BA83.55-P-1001-01C

Screw, refrigerant compressor to timing case cover

Nm

20

 Refrigerant compressor

Number

Designation

Engine 642 in model 461

BA83.55-P-1001-01TU

Bolt, refrigerant compressor to timing case and left engine support

Nm

20

 Refrigerant compressor

Number

Designation

Engine 611.960/961/962, 612.961/962/963/965/966/967/990, 613.960/961

BA83.55-P-1002-01C

Screw, refrigerant compressor to bracket

Nm

20

 Refrigerant compressor

Number

Designation

Engine 642 in model 461

BA83.55-P-1002-01TU

Bolt, refrigerant compressor to bracket

Nm

20