11. Locate belt tensioner air pressure valve on the
upper right corner into the engine compartment.
12. Rotate the lever to release belt tensioner air
pressure.

FIGURE 5

13. Disconnect high and low pressure hoses on the
existing compressor.

FIGURE 6

14. Disconnect high and low pressure hoses to the
AC system tubes.
15. Discard the hoses.

FIGURE 7

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16. Cut all cable ties that secure the existing
compressor wirings and connectors.
17. Locate connector L199 (Unloader RH).
18. Cut orange existing orange wire (#31) and
existing black wire (#0RA4) flush to the L199
connector. Keep label L199 on the wire.

FIGURE 8

19. Locate connector L200 (Unloader LH).
20. Cut existing orange wire (#33) flush to the L200
connector.

FIGURE 9

21. Install 2’’ of black shrink tubing on the existing
orange wire #33 and heat it to make it watertight.
22. Disconnect all remaining wire connectors on the
existing compressor.
FIGURE 10

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23. Remove screws on the curb side.

FIGURE 11

24. Remove screws on the engine side.
25. Discard existing AC compressor and existing
fasteners.

FIGURE 12

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MOUNTING THE CLUTCH ON THE COMPRESSOR
26. Before installing the clutch, dismount the oil
tube on the left side of the shaft. The tube is
installed on the opposite side. Keep the
support and the fasteners.

FIGURE 13

27. The flange and the shaft end must be free from
dirt.
28. Apply high temperature approved assembly
grease on the shaft end for easy dismounting
of the clutch. Use of Molykote G-rapid-plus or
Molykote P 40 is recommended.

FIGURE 14

29. Install the coil. Slip the coil on the compressor
flange. The cable connector must be
positioned on the right side as shown in Figure
15.

FIGURE 15

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30. Fix the coil with 4 screws PN 5001775. Use
Loctite 243 blue on each screw.
31. Torque the screws to a value of 20-24 lb-ft.

CAUTION
Pay attention to the precise seat of the coil. A
non-observance may cause the destruction of
the clutch components during the operation.
FIGURE 16

32. To avoid damaging the rotor bore, make sure
that the woodruff key supplied with the clutch is
positioned as shown in Figure 17, otherwise, it
could move when the rotor is inserted on the
shaft end.

FIGURE 17

33. Carefully mount the rotor on the shaft end by
hand. Never use a hammer for pressing the
rotor on.

NOTE
To avoid damaging the bore of the rotor, feel
the engagement of the key in the keyway and
slip the rotor on the shaft end of the
compressor till reaching the stop.

FIGURE 18

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34. Fasten the rotor to the shaft end by using the
M12 screw supplied with the clutch and
holding-up with a wrench on the hexagonal
part of the rotor. Apply blue Loctite 243 on the
screw.
35. Tighten the screw to a torque value of 60 lbf-ft
(81 Nm).

NOTE
Turn rotor by hand and pay attention to the free
run and the generation of noises. In case of
rubbing, grinding or similar noises, dismount
the rotor and check installation.

FIGURE 19

36. Once properly tighten, apply a torque seal
mark.

FIGURE 20

37. During cleaning or other work on the
compressor, the clutch must be covered to
prevent the penetration of greasy liquids,
grease or dirt particles in the working gap of
the clutch. No high pressure cleaning.

NOTE
Working gap must be between these values:
0.024 in - 0.035 in (0.60 mm - 0.90 mm)
FIGURE 21

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BITZER AC COMPRESSOR INSTALLATION
38. If necessary, replace rubber bushings PN
630062.

FIGURE 22

39. Install cable tie mount on the bottom wire
support. Use table below for the components.

069481

BOTTOM WIRE SUPPORT

1

504340

POP RIVET 1/8’’

1

504810

CABLE TIE MOUNT SMALL SIZE

1

FIGURE 23

40. Install cable tie mount on the middle wire
support. Use table below for the components.
069450

MIDDLE WIRE SUPPORT

1

504340

POP RIVET 1/8’’

1

504810

CABLE TIE MOUNT SMALL SIZE

1

FIGURE 24

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41. Install cable tie mounts and fir tree mounting
on the top wire support. Use table below for
the components.
067349

TOP WIRE SUPPORT

1

504379

POP RIVET 3/16X1/4

2

504013

CABLE TIE MOUNT BLACK 1/4"

2

509815

FIR TREE MOUNTING (FT7)

2

FIGURE 25

42. Prepare Carrier to Bitzer special support (PN
7770442) for installation.

FIGURE 26

43. Install special support (PN 7770442) on the
existing compressor support with two screws
on the pulley side. Use table below for
components.
500197

SCREW 3/8X1LG

2

500265

NUT STO 3/8

2

500832

FT WASHER 0.41 ID

2

44. Do not tighten the screws.

FIGURE 27

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45. Complete installation of the special support
(PN 7770442) on the existing compressor
support with two screws on the back side. Use
table below for components.
500086

SCREW1/2X1.5LG

2

500718

NUT STO 1/2-20

2

500211

FLAT WASHER 1/2 ID

2

46. Do not tighten the screws.

FIGURE 28

47. Install new compressor on the special
support. Prepare to install the bottom wire
support with the screw on the pulley side.

FIGURE 29

48. Install new compressor on the special support
with 4 screws. Use table below for the
components.
5001338

SCREW M12X45LG

4

500967

WASHER BEL 1/2

4

500811

NUT STO 1/2

4

49. Torque the screws to a value of 74 lb-ft.

FIGURE 30

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50. Check alignment between engine pulley and
compressor pulley.
51. Use an electronic level for the vertical
alignment and install shim if necessary.
52. Use a rule for the horizontal alignment.
Compressor support has arced slot to
facilitate the horizontal alignment.
53. Tighten the screws (4) that hold the special
support with the existing compressor support.

FIGURE 31

54. Clean the hose fittings and the new O’Rings.
55. Lubricate both O-Rings with compatible 134-A
AC oil before installation on the fittings.
56. Install new O’Ring on the new hose fittings.

FIGURE 32

57. Connect new high-pressure hose and new
low-pressure hose to the AC system tubes.
Use table below for components.

950493 HIGH-PRESSURE HOSE

1

950489 LOW-PRESSURE HOSE

1

501802 O'RING #16

1

501803 O'RING #20

1

FIGURE 33

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58. Add seal marks on both fittings.

FIGURE 34

59. Clean hose mounting faces (new compressor
and new hose flanges).
60. Connect high pressure hose and low-pressure
hose to the AC compressor.
61. Use new gasket PN 950957 on both flanges
62. Torque flange screws to 31-35 lb-ft (42-47
Nm).
63. Add torque seal marks on all flange screws.

FIGURE 35

64. Install hose clamps around the mid-distance
of the hoses as shown in Figure 36. Use table
below for components.
65. Make sure to keep a clearance between the
hoses and the side door.

N31320-07

CLAMP LOOP TYPE

2

474304

BOLT 1/4-20

1

500411

WASHER 1/4

2

5001123

NUT 1/4-20