Leaking Or Damaged Areas, Replacing, Empty Refrigerant Circuit Except A/C Compressor And Receiver/Dryer
The Refrigerant Circuit Was Completely Empty (for Example with Larger Leak or Cracked Hose)
- Pay attention to the general information for replacing components. Refer to GENERAL INFORMATION FOR REPLACING COMPONENTS .
In the event of only a minor leak with slow escape of refrigerant (for example at a small leakage point), the amount of refrigerant oil lost and the amount of moisture penetrating after servicing is not sufficient to influence operation of the air conditioner.
The operations marked* are only to be implemented in case of a major leak (for example following an accident).
-- Remove The Faulty Component.* Refer to the appropriate information (REFRIGERANT CIRCUIT / REFRIGERANT CIRCUIT / REFRIGERANT CIRCUIT ) (vehicle-specific repair information).
-- Clean the refrigerant circuit (flush with refrigerant R1234yf). Refer to REFRIGERANT CIRCUIT, CLEANING .
Electrically-Driven A/C Compressor
-- Remove the electrically-driven A/C compressor and clean (flush with refrigerant R1234yf)*. Refer to REFRIGERANT CIRCUIT, CLEANING and A/C COMPRESSOR / A/C COMPRESSOR, REMOVING AND INSTALLING (vehicle-specific repair information).
Mechanically Driven A/C Compressor
-- Remove A/C compressor.* Refer to A/C COMPRESSOR / A/C COMPRESSOR, REMOVING AND INSTALLING (vehicle-specific repair information).
-- Remove The Oil Drain Plug -B / D- From The A/C Compressor -A-.*
The Versions Of The Oil Drain Plug -B / D- and The Seal -C / E- Are Different (Depending On The Manufacturer Of The A/C Compressor). Refer to A/C COMPRESSOR / A/C COMPRESSOR, REMOVING AND INSTALLING (vehicle-specific repair information).
When installing the oil drain plug -B / D- note the tightening specification (depending on the manufacturer of the A/C compressor and the version of the oil drain plug) on "Denso" and "Delphi" A/C compressor is for example installed on the oil drain plug (tightening specification currently 30 Nm on "Denso" and 15 Nm on "Delphi" A/C compressor). On "Sanden" or "Zexel- / Valeo" A/C compressors an oil drain plug or a seal is installed depending on the version on the oil drain plug (tightening specification currently 10 Nm).
On Denso A/C compressors for example a seal -E- is installed on the oil drain plug -D-. Refer to A/C COMPRESSOR / A/C COMPRESSOR, REMOVING AND INSTALLING (vehicle-specific repair information) and the Parts Information for replacement.
On Sanden A/C compressors for example a seal -C- is installed on the oil drain plug -B-. Refer to A/C COMPRESSOR / A/C COMPRESSOR, REMOVING AND INSTALLING (vehicle-specific repair information) and the Parts Information for replacement. Refer to A/C COMPRESSOR (vehicle-specific repair information) for the tightening specification.
If the seals (seal or O-ring) that are installed on the oil drain plug are not available as a replacement part, the removed seals may be used as an exception (check for damage before installing). If the removed seal is damaged or deformed if necessary replace with a commercially available component.
After charging the refrigerant circuit check the installed oil drain plug for leaks for example using an electronic leak detector.
To accelerate drainage of refrigerant oil, turn the A/C compressor via the belt pulley or the A/C clutch plate, for example.
-- Drain the old refrigerant oil from the A/C compressor. Refer to A/C COMPRESSOR, REPLACING WITHOUT THE NEED FOR FLUSHING REFRIGERANT CIRCUIT .
All Vehicles
-- Fill the specified complete oil quantity in the A/C compressor or the circuit. Refer to A/C COMPRESSOR, REPLACING WITHOUT THE NEED FOR FLUSHING REFRIGERANT CIRCUIT and TECHNICAL DATA (REFRIGERANT & APPROVED OIL CAPACITIES) or MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (1 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (2 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (3 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (4 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (5 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (6 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (7 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (8 OF 8) (CABRIOLET) (The approved refrigerant oil and capacity for the refrigerant oil can be found in the vehicle-specific repair information).
Then Fill A/C Compressor With Quantity Of New Refrigerant Oil Corresponding To Quantity Of Refrigerant Oil In Replacement A/C Compressor.* Refer to TECHNICAL DATA (REFRIGERANT & APPROVED OIL CAPACITIES) or MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (1 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (2 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (3 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (4 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (5 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (6 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (7 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (8 OF 8) (CABRIOLET) (vehicle-specific repair information).
Use the different refrigerant oils and quantities for the different A/C compressors. Refer TECHNICAL DATA (REFRIGERANT & APPROVED OIL CAPACITIES) or MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (1 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (2 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (3 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (4 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (5 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (6 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (7 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (8 OF 8) (CABRIOLET) (vehicle-specific repair information).
To ensure compressor lubrication on start-up, at least 40 cm3 of refrigerant oil must be poured into the compressor. The remainder can be added to the new reservoir/receiver/dryer or a refrigerant line. Refer to (vehicle-specific repair information).
If on an open refrigerant circuit dirt enters the A/C compressor (for example during an accident) the A/C compressor must be replaced. Refer to TECHNICAL DATA (REFRIGERANT & APPROVED OIL CAPACITIES) or MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (1 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (2 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (3 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (4 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (5 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (6 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (7 OF 8) (CABRIOLET) / MAINTENANCE (FLUID CAPACITY TABLES), DIAGNOSIS (8 OF 8) (CABRIOLET) (vehicle-specific repair information).
Clean the refrigerant circuit (flush with refrigerant R1234yf). Refer to REFRIGERANT CIRCUIT, CLEANING .
-- Replace The Dryer Cartridge And Receiver/Dryer.* Refer to RECEIVER/DRYER, REMOVING AND INSTALLING / DRYER BAG/DRYER CARTRIDGE, REMOVING AND INSTALLING / CONDENSER, REMOVING AND INSTALLING (vehicle-specific repair information).
-- Assemble, evacuate and recharge the refrigerant circuit. Refer to WORKING WITH A/C SERVICE STATION .