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AC Compressor DIY I4
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Posted by jeff02 [Email] (#2992) [Profile/Gallery] (more from jeff02) on Sat, 25 May 2013 21:48:26 Share Post by Email
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Just replaced an AC Compressor. Thought I would write it up.

Symptoms for Bad Compressor / Clutch

1) No cold air at all
2) Coolant pressure in system

Test for Bad Compressor Clutch

1) Remove Headlight and side light on compressor side
2) Take apart the one power connector going to the compressor clutch
3) With engine stopped, jumper compressor clutch side connection to battery +12
4) Should hear a subtle CLICK from the compressor clutch, if no CLICK bad clutch
5) Test with multimeter that the wire going from the screw on the compressor is grounded, if not fix and redo 4
6) Slightly strip the +12 wire past the connector and redo 4) to eliminate problem with connector, if still no click, bad clutch
7) If clutch click, test feed line that +12 is present with car running and HVAC set to LOW temp.
8) If no +12 feed, need to check upstream for problem and / or check pressures in system with AC Manifold or the like. There are a low pressure and high pressure cutoffs or fuses, etc.
9) Good pressures should be 30+ on low side ant 150+ on high side (with Compressor Running). If this checks out compressor is working fine.
10) If +12 feed and either no clutch click and still no cold air (low high side), replace compressor.

Replacing Compressor

1) Jack up car on compressor side and secure. Place jack stand under engine for support
2) Remove pipe from cobra on top and on top of engine mount and remove. Be careful of banjo bolt copper washers
3) Remove the engine mount
4) Remove pipe from lower cobra pipe and attached to turbo inlet pipe and remove sensor on turbo inlet pipe
5) Place container under car where the top radiator pipe comes in
6) Remove bottom plastic front panel
7) Remove two bolts holding fan unit on (and one on bottom) and remove the power connections for the fan
8) Remove the upper coolant hose plug radiator if you want to, or let drip out. Some will but not much.
9) Remove the fan housing
10) Temp replace the coolant hose on radiator (thanks Matt)
11) Remove belt from compressor
12) Remove 2 bolts retaining the AC lines. Take care removing the lines from the compressor.
13) Remove three AC Compressor mounting bolts, two from below, one from above using open end wrench with ratchet
14) AC comes out down though frame. Take care of clutch wire.

Replace in reverse order.

Any comments?

JeffO2
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