Morning all

I'm in desperate need of some assistance, i have searched the web, gone through the workshop manual but still can not find a solution to removing the air conditioning compressor.

I have had the car up on ramps, removed the under trays and due to very limited access i can not see it being removed from below, i then switched to the top, i removed the following.

• Air filter box
• Radiator expansion tank
• Intercooler hoses
• Radiator hoses
• Serpentine belt (just as well as mine had split into two parts)
• Removed the top idler pulley(helps remove the radiator pipe from the block that's situated above the compressor)

That's as far as i got because i still can't see away to gain full access to the compressor.

Can anyone give me any tips, DIY links or pointers on the process for removing the compressor.

Thanks in advance.

 

I have the workshop manual but it's not much help??

You do need to remove the plastic cooling tubes that the radiator hoses attach to.
Have you removed them?

Here are 6 pages from the manual for the 3.0L Diesel. See if they make any sense??











So very poor instructions and I have a SC 5.0L V-8 in my XJ so I can't take a look and see what needs to be done.
I "think" the bolt in step 11 is the idler bolt you mention as being removed already? If so your on the right track but have not removed enough stuff yet.

I really recommend getting a manual. We have them posted for free in the top of the forum stickies. Well worth the price!!
Note this is where all the above pictures came from.

You need to also finish this thread with your tips so the next guy can befit from your troubles. Remember this is a US forum and we never got the diesel so none over here and we don't have any experience with fixing them.
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Afternoon
Thanks for the quick reply, i followed the instructions in the manual, except this part.

I guess that's covered in the Turbo Bypass valve, i couldn't figure out how to remove that part, any pointers. i'm going to book Thursday and Friday off work to give it another go, should be a bit cooler too

 

I did not understand that picture either? That's why I said I wish I could take a look at a car with that engine. Might make more sense then?
Does it need to be removed or not? Can it be removed?
Manual does not say.
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Its the turbo bypass valve and it sits right on top of the compressor restricting access the back of the compressor and the 2 ac pipes that connect to the compressor, thats as far as i got at the weekend before i gave up and put it all back together again.

 

Well I managed to swap out my air conditioning compressor this Friday and had it re-gassed yesterday, I’m pleased to say that its working great.

The job its self was a right pig, took me 9 hours total I wasn’t in a hurry and I had a few heavy rain showers during the day that necessitated downing tools for a while.

To remove the compressor requires access from underneath the car and the top through the engine bay at the same time.

The worst part of the job was loosening the hose clips to remove coolant hoses and intercooler hoses, access is really tight and its very awkward to get them loose (then having to retighten after) this took up the majority of the time.

Steps to gain access were:

1. Raise the front of the car, just enough to remove the bottom engine cover, you need enough room under there to work but not too high as you still need to work from the top of the engine bay at the same time.

2. Remove the air box

3. Remove the LH intercooler hose(was connected to the airbox) there is a moulded bracket with a 10mm nut that fixes this to the engine block, just below the top idler pulley, at the end of this plastic hose it a hose clip that’s needs loosening also(access to the hose clip is really hard)

4. Remove serpentine belt(not completely but remove from the AC compressor and top idler pulley.

5. Remove top idler pulley(3 x 10mm bolts) you need to remove this to gain access where coolant hose goes into the block to remove the hose clip.

6. Remove the LH Intercooler to turbo relief valve hose.

7. Remove the LH lower intercooler hose, rubber 90 degree bend that connects to the stainless charge pipe and the turbo relief valve that’s sits at the bottom of the radiator. Again the hose clips are a pig to get access to.

8. Remove the stainless charge pipe, it fixed to the block by a bracket, access to this bolt is from underneath the car, the top hose clip again is a right pig and it situated by the top strut panel.

9. Remove the plastic intercooler pipe that extends out of the turbo, this was the pipe that the LH intercooler pipe was connected to(number 3 above), just pull it away from the turbo and angle it towards the top strut panel.

10. From under the car remove the AC pipe bracket that connects to the bottom of the AC compressor, while you are under there by the transmission bell housing there is another AC pipe fixing point that need to be taken off.

11. From the top of the car you can now take off both AC pipes that connect to the compressor, they are 13mm nuts 2 in total, you can’t really see these so you are doing this by feel only.

12. Carefully lift up and remove the AC pipes to one side.

13. The compressor is held on with 3 10mm long bolts, once these are off you can remove the compressor, the front bottom bolt will not come away from the compressor (no room) so take off the compressor with it still sitting loose in its hole, important to remember when re-fitting the compressor to place this bolt into the compressor before attaching back to the car.

Re-fitting is the reverse of the removal process.

Good Luck.

 

Definitely a lot of work!
Good job!
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