Electromagnetic Clutch: Compressor

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Special tools:

9995474

WARNING: Follow the safety rules for work with the heating/ventilation system, see Safety Instructions When Handling Refrigerant

Read the instruction about slow and fast leakage, see Oil In the A/C System .

General

Fig 1: Mudflap And Screw

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Always change O-rings when replacing compressor.

Drain the refrigerant from the system, see Draining and recycling refrigerant

Disconnect the battery negative lead.

Remove the mudflap.

Remove the multi-groove V-belt

Protect the radiator with 9995474

Loosen connections for the compressor hose

Fig 2: Compressor Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the bolt(s).

Disconnect the hoses.

Carefully seal the openings.

Remove the compressor

Fig 3: Compressor, Support And Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect the connector from the compressor.

Remove the attaching screws.

NOTE: There is an extra support in gasoline-powered cars

Remove the compressor.

Remove the support for the connector.

NOTE: If the compressor is replaced, the oil volume shall be determined, see Oil in the A/C system .

Install new O-rings on the filler plug (lube with compressor oil) and tighten with 15 Nm.

Change oil also if the compressor is not replaced.

Install the compressor

Fig 4: Compressor Bolts With Torque Specifications

Courtesy of VOLVO CARS OF NORTH AMERICA.

Gasoline cars: Install the support for the connector.
Install the hose, tightening torque:
- Zexel 22 Nm.
- Sanden 45 Nm.
- MSC90 25 Nm.
Install the compressor and tighten the bolts with 40 Nm (gasoline cars), 21 Nm (diesel cars).
Install the hose, tightening torque:
- Zexel 22 Nm.
- Sanden 45 Nm.
- MSC90 25 Nm.
Connect the connector.
Install the hose, tightening torque:
- Zexel 22 Nm.
- Sanden 45 Nm.
- MSC90 25 Nm.
Lube the new O-rings with compressor oil.
Install the hose, tightening torque:
- Zexel 22 Nm.
- Sanden 45 Nm.
- MSC90 25 Nm.

Fill the system and check for leaks, see Draining And Recycling Refrigerant .
Install the multi-groove V-belt.
Install the mudflap.
Check the function.
Read off the diagnostic trouble codes (ECC-system).

Change pressure monitor

Fig 5: Pressure Monitor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Drain the system, see Draining And Recycling Refrigerant

Unplug the connector and twist loose the pressure monitor.

Lube the new O-rings with compressor oil.

Tightening torque for pressure monitor: 18 Nm.