Air conditioning system:

Prior to removal and/or installation of the spare part it must be verified that connections, fixings and other installation-relevant properties are identical.

When replacing components, always use new O-rings suitable for the refrigerant.

The compressor oil has a strong hygroscopic effect. Thus, the system must be kept closed if possible and/or the oil is to be filled shortly prior to closing the refrigerant circuit only.

Prior to the installation, O-rings and seals are to be greased with refrigerant oil or special lubricants in order to facilitate installation. No other greases or silicone spray may be used as this results in immediate contamination of the new refrigerant.

For every opening of the refrigerant circuit the dryer must be replaced due to its strong hygroscopic effect. If dryer or accumulator are not replaced on a regular base, the filter pad may decompose and silicate particles may be distributed in the entire system and cause severe damage.

The system connections should never remain open for an extended period of time, but should be immediately closed using caps or plugs. Otherwise, liquid would be entered together
with air into the system.
In order to avoid damage to connection pipes and/or components, always use two wrenches when loosening and fastening the connections.

When routing tubes and cables make sure that no damage is possible caused by vehicles edges or other moving components.

When replacing a component of the air conditioning system, the correct oil quantity in the system is to be ensured. Oil must be refilled or drained as needed.

Prior to refilling the system, it must be checked for leaktightness. Next, the system is to be sufficiently evacuated (approx. 30 minutes) in order to ensure that all humidity is removed from the system.

Pressure gauge

Filter dryer

O- ring set

After filling the refrigerant quantity specified by the vehicle manufacturer, the system is to be checker for proper function and leak-tightness (electronic leak indicator). At the same time, the high and low pressure values must be observed using pressure manometers and compared with the specified values. Compare the outflow temperature on the centre vent with the values specified by the manufacturer.

After the service connections are fitted with protective caps, the maintenance due date is to be indicated on an adhesive service label on the front cross member.

Information regarding the installation of air conditioning system compressors:

Make sure that all contaminations and foreign substances are removed from the refrigerant circuit. For this purpose, the system is to be flushed prior to installing the new compressor. Depending on the level of contamination, refrigerant R134a or a special flushing solution is suitable for flushing. Compressors, dryers (accumulators), expansion valves and/or orifice tubes cannot be flushed. As it must always be assumed and cannot be
ruled out that the system is contaminated (abrasion, swarf) when a compressor is defective, the system must always be flushed when this component is replaced. Make sure that no flushing solution residues remain in the system. Dry the refrigeration circuit using nitrogen as needed.

Replace the filter dryer or accumulator and the expansion valve or orifice tube.

Electronic leak indicator

PAO-Oil 68

As one and the same compressor can potentially be used for different vehicles or systems, the oil filling quantity and viscosity must be checked and/or corrected according to the manufacturer's specifications before installing the compressor. All the oil must be siphoned off and collected. The compressor must then be newly filled with the entire oil quantity specified by the vehicle manufacturer (system oil quantity).

The compressor must be spun 10 x by hand before being installed to ensure the oil is distributed evenly. When installing the drive belt it must be ensured that it is aligned. Some compressors are designed for so-called "multiple applications". This means that they can be installed in different vehicles. Except the number of grooves on the magnetic clutch, there is 100% agreement with the "old part".
After compressor installation and new filling of the refrigerant circuit, the engine should first be started and operated for several minutes at idling speed.

Further specifications (instruction leaflets, manufacturer's specifications, run-in specifications) are to be separately observed.
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