1. Mike rolls in his special air-con machine; connects one pipe into the high pressure line (the thicker one) and one pipe into the thinner the low pressure line. This allows him to collect the CFC gases safely.
2. Unbolt the hose manifold and free it from the main unit.
3. Disconnect the wiring which runs to a single connector in the electric box (remove plastic cover to gain access).
4. Undo the main mounting bolts. Be sure to secure the square M8 nuts which can fall and get lost in the darkness of the engine bay.
5. Remove old hose 'head' from manifold, and using some emery cloth clean up the surface before securing onto new unit (which should come with new gasket and fully oiled).
5. On the bench and in the vice, Mike bolts the old hose 'head' onto the shiny new unit.
6. A little rethreading to remove any surface rust / residue to ensure bolts go in easier than they were to take out.
7. Using emery cloth again clean up surface of hose manifold before securing onto original 'head', now mounted onto new compressor unit. Replace old O-Rings with new ones as it's likely that the original ones would have perished causing them to leak / fail. Also rub with the same compressor oil (PAG) to ensure better fit.
8. Bolt the main compressor unit back onto the mounting plate and into the engine bay. Before securing Mike plays around with the adjusting bolt (which slides the unit back and forth on one axis) finding the right position to give the belt it's correct tension (approx. 10mm of play). Then connect old manifold back onto 'head'.
9. Plug back onto the special air-con machine and re-gas. The system also pushes dye through the system so should any other leaks appear they can easily be identified. We got up to full pressure and no signs of any dye - so job done.
10. A nice new shiny compressor. For the first time since I've owed the car, she was blowing cold. Just in time for the summer. Nice.
Thanks Mike for a sterling job.
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