NHTSA ID Number: 10130109
Manufacturer Communication Number: 122-E5S5K-03
TSB/Document Date: 2018-03-13
Summary
Replacing air-conditioning compressor during repairs. If a faulty air-conditioning compressor needs to be replaced, an air-conditioning compressor of similar design is available. The fastening points are not the same as on the standard air-conditioning compressor. The high-pressure and low-pressure lines must be changed!
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Air-Conditioning Compressor
Vehicle Type:
928/S Coupe/928 S4 Coupe/928 GT Coupe/928 GTS Coupe
Model Year:
As of 1980 up to 1989
Concern:
Replacing air-conditioning compressor during repairs.
Notes:
If a faulty air-conditioning compressor needs to be replaced, an air-conditioning compressor of similar
design is available.
The fastening points are not the same as on the standard air-conditioning compressor. The high-pressure
and low-pressure lines must be changed!
Parts Info:
928.126.010.71
1x
Air-conditioning compressor, complete, set
Also order the following, depending on model year:
928.573.089.10
Intake pipe (low-pressure hose) - 1980 to 1986
928.573.089.11
Intake pipe (low-pressure hose) - 1987 to 1989
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Parts list:
Figure 2
Materials:
Tools:
———
1x
Air-conditioning compressor assembly (ASSY) Figure 2 -1-
———
1x
———
1x
Fastening material for compressor, comprising Figure 2 -2-:
1 x hexagon-head bolt, M10 X 50 DIN 933
1 x M10 hexagon nut, self-locking DIN 985
1 x M10 washer DIN 125
2 x M10 washer (25x4) DIN 7349
Strut Figure 2 -3-
000.043.305.79
1x
Refrigerant oil (as required)
———
1x
Refrigerant R134a, approx. 850 +/- 25 g
Locally available R12 Recovery Machine, or if converted to R134
Locally available R134 Recovery Machine
Rubber gloves (commercially available)
Protective goggles (commercially available)
Thermometer
WARNING
Refrigerant
•
Danger of freezing
Avoid contact with refrigerant.
Wear personal protective gear.
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Observe the safety regulations for working on air-conditioned vehicles and dealing with refrigerant.
Observe the safety regulations for extraction and filling systems.
Observe the instructions for repairing air conditioning systems and storing spare parts.
Work Procedure: 1
8
Preparatory work:
1.1
Remove air intake hose Figure 3 -1-.
Figure 3
WARNING
Toxic substances
•
Danger of poisoning or suffocation
Ventilate the work area well.
Never ingest or inhale.
Read specific information on the MSDS Sheet.
Wear personal protective gear.
Information
1.2
2
•
On air-conditioning service equipment with a transparent oil separator, read and take
note of the oil level before removing refrigerant.
•
Do not carry out this step on empty air-conditioning systems (pressure gauge approx. 0
psi/bar) because if you do, air will get into the refrigerant bottle.
•
If the vehicle is cold, it may be necessary to repeat the suction procedure until all
refrigerant has been removed from the air-conditioning system. This step is carried out
automatically with some units.
Remove refrigerant by suction. see 8701 87 01 Connecting service equipment to the
air-conditioning system.
Remove air-conditioning compressor.
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2.1
Disconnect plug connection for solenoid
switch Figure 4 -1-.
Figure 4
2.2
Unscrew union nut Figure 5 -1- from
low-pressure hose.
Counter at the lock nut Figure 5 -2-.
2.3
Remove underbody panelling.
Figure 5
2.4
Remove strut (for air-conditioning
compressor) Figure 6 -1-.
2.4.1
Slacken the air-conditioning
compressor V-belt.
Unscrew M8 hexagon nut Figure
6 -2- and unscrew hexagon-head
bolt (M10 x 33) Figure 6 -3-.
2.4.2
Unscrew hexagon-head bolt (M8 x
28) Figure 6 -4-.
Figure 6
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2.5
Unscrew hexagon nut Figure 7 -1- and
remove strut (for secondary air injection
pump) Figure 7 -2-.
2.6
Remove compressor.
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Figure 7
2.6.1
Unscrew hexagon-head bolts
Figure 8 -1-.
2.6.2
Remove V-belt and lower the
compressor.
Figure 8
2.6.3
3
Unscrew union nut from
high-pressure hose Figure 9
-1- and remove air-conditioning
compressor with low-pressure
hose.
Work steps for blocked/seized up air-conditioning
compressor
3.1
Remove desiccator.
Figure 9
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WARNING
Toxic substances
•
Danger of poisoning or suffocation
Ventilate the work area well.
Never ingest or inhale.
Read specific information on the MSDS Sheet.
Wear personal protective gear.
Information
3.2
•
If there are chips in the system, the air conditioning must be flushed.
•
When using air conditioning service equipment with a flushing function, follow the
procedure described in the operating instructions provided by the relevant manufacturer.
•
If you only have access to air conditioning service equipment without a flushing function,
it is still possible to flush the air conditioning system in the conventional way. See
description below.
Check connections on the condenser, on the desiccator and at the refrigerant lines for the
desiccator for signs of wear/chips.
Is there wear/chips?
•
•
YES: Continue with 3.2.1
NO: Continue with 3.3
3.2.1
Remove refrigerant line between compressor and condenser.
WARNING
Toxic substances
•
Danger of poisoning or suffocation
Ventilate the work area well.
Never ingest or inhale.
Read specific information on the MSDS Sheet.
Wear personal protective gear.
3.2.2
Feb 22, 2018
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Flush refrigerant line between the compressor and condenser using a suction and
pressure adapter and commercially available acetone. The acetone dissolves the
refrigerant oil in the air-conditioning line.
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3.2.3
Allow the acetone to dry off in the refrigerant line.
3.2.4
Wrap bright fabric around the refrigerant line connection between the compressor
and condenser and secure it on the line with a tie-wrap.
WARNING
Working with compressed air
•
Risk of eye injuries
•
Risk of damaging and dirtying components
Wear protective goggles with side eye protection.
Protect the point at which the compressed air emerges with suitable material.
Place the point at which the compressed air emerges on suitable surfaces.
3.3
3.2.5
Blow out refrigerant line between the compressor and condenser using pure
compressed air (with NO oil or water mixed in).
3.2.6
Replace condenser and desiccator.
3.2.7
Install refrigerant line between the compressor and condenser.
Replace desiccator.
NOTICE
Too much or too little refrigerant oil in air conditioning circuit
•
Reduced cooling output
•
Lack of lubrication and failure of the air conditioning compressor
If a new air conditioning compressor or a component in the circuit is replaced, the oil quantity must be
checked and adjusted.
4
Check and measure the refrigerant oil level in the air-conditioning compressor/cooling system.
4.1
4.2
ONLY for air-conditioning compressor WITHOUT oil drain plug:
Measure refrigerant oil quantity of "old" air-conditioning compressor.
4.1.1
Open the oil filler screw on the air-conditioning compressor.
4.1.2
Fill refrigerant oil from the air-conditioning compressor into a measuring cylinder.
Turn the pressure plate on the air-conditioning compressor (not the pulley) when
emptying refrigerant oil.
4.1.3
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TSB/Document ID: 122-E5S5K-03
Replacement Service Bulletin Number:
MFR Communication Date: 2018-02-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:COOLING SYSTEM
MFR Component System:
MFR Component Subsystem:
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