AC Compressor Repair: Fix Your Air Conditioning!

Hello fellow enthusiasts,

da mein Klimakompressor am Golf 3 1Z Bj.: 12/94 294000 Km Geräuche gemacht hat, die sich nach einem Lagerschaden anhören, habe ich diesen ausgebaut. Nand my question is:
Has anyone ever tried to repair an air conditioning compressor? If so, what should you be aware of? The mechanics at the workshop told me that the magnetic clutch needs adjustment. What does that mean? Can you avoid having to adjust it by marking something appropriately?
Please share your opinions and tips.

Thank you.

Gregor.

hi!
I once disassembled a swashplate compressor for a training course. It no longer has a magnetic coupling, so I can't offer any advice on that specific aspect. However, regarding the internal components, I wouldn't open it again because the balls (used to support the swashplate) were all mixed up and out of place. Normally, they should have been returned to their original positions. I suspect there are special assembly aids for reinstalling them. Otherwise, it wouldn't be possible. Furthermore, there is a relatively large amount of oil inside the compressor, so you should only work with gloves on. Otherwise, your hands will look like they're dried out after a short time...
I also think that the sealing might be a problem in some cases.

Best regards,
pretzel

Adjusting the magnetic coupling refers to the following:

The clutch consists of two parts: the outer rotor (which always rotates) and the coupling, which is mounted on the compressor shaft. This coupling consists of a fixed bearing that sits on the shaft and is connected to an outer ring via three flexible metal strips. This outer ring runs very close (I believe 0.6 mm) laterally above the outer ring. When power is applied to the outer rotor (which contains coils), the outer ring is magnetically attracted. This completes the coupling process.

'By 'setting', we mean the distance between the outer runner and the outer ring. Therefore, you must completely assemble the coupling and then check this distance while it is assembled. If this distance is incorrect, spacer rings must be placed on the compressor shaft until the correct distance is achieved.'

If the distance is too small, it will rub; if it's too large, the metal lamellae will eventually break. That's what happened to me. Unfortunately, the compressor was standard equipment. However, this part with the metal lamellae isn't sold separately; it only comes as a complete unit with the AC system for around 500 EUR. I then got one from a Golf Mk2. It has been working perfectly ever since.

The problem is only removing the disc, as it uses some kind of 1/4' left-hand threads. However, a radiator installation company helped me with this issue. They had the right tools to remove it.

Hello,

Loose balls in a thrust ball bearing can be secured with grease.
I just think that doesn't belong in a climate control compressor. Maybe after successfully assembling it with a solvent, you should flush it and manually turn the compressor.

Best regards, Rainer.

Hello Rainer!
We had the same idea about using grease back then, and we even tried it. However, despite our efforts, we couldn't reassemble the compressor in a way that would make it functional again. Thankfully, it was just a test object that didn't need to function anymore. I share your concerns about whether grease belongs inside a compressor. In my opinion, I wouldn't use it in my own compressor. And you won't be able to remove it with flushing either. I can also imagine that grease residue could potentially clump together over time and hinder the closing of the very thin reed valves.


Best regards,
dirk