2005 2.7D Auto A/C compressor replacement.

[mrmike]

Has anyone replaced the A/C compressor on a 2.7D, I took the car to an indie garage with the replacement compressor. After 2 days he called me and said it was too complicated.

In the manual, from page 2662 does not seem too bad, I have the new compressor seals. Another question I have is about the Oil for the Comp, is this in with the gas or a separate compartment of the compressor? This appears to be introduced into the compressor before remounting?

[mrmike]

OK started today, Having a problem removing the header tank, the plastic connector pipe doesn't seem to want to come off. soaked it in Oil when it got too hot here to work on it, hopefully tomorrow I can free it up. The coolant level connector had been removed and insulated??? The A/C compressor is just visible now but how I will get it out is anyone's guess. Top view is blocked by the Steering pump. Tomorrow Am back on it.

[mrmike]

Having spent half of my time removing the rubber tube clamps in the most awkward positions I have come to the Auto box Heat exchanger.

Getting the auto box heat exchanger out is a really good one, first without the jag clamp tool it is a nightmare but I eventually removed the top

hose clamp. Great I thought now we are getting somewhere, Wrong It doesn't come out! Why because there is a piece of !Removed! plastic underneath it.

What isn't mentioned (Traitors) is that the plastic mount is held by 2 recessed 13mm bolts under the heat exchanger. Getting at them is a real battle with the

limited movement of the heat exchanger. Removal of this took 6 hours in all not counting soaking overnight of the rubber pipe to the overhead plastic "T" piece.

After around 12 hours I am ready to Start on the A/C compressor itself. Interestingly the transmission fluid was dark red, sucks of Dexron or some other cheapo fluid

that is NOT to be used on the ZF 6 speed auto box.

More Tomorrow hopefully with a new compressor fitted.

[mrmike]

I intend to eliminate this heat exchanger after the summer with a separate radiator given that these HEs are somewhat unreliable.

[mrmike]

I should have added that I will not refit it with the bolts but with tie raps until I complete the mod.

[mrmike]

OK Today I finally removed the A/C Compressor. The manual is "WRONG" in many ways as are the pictures.  Do not listen to those that say the Compressor comes out below, Believe me unless it is shrunk by some miraculous Jaguar atomic shrinker to a quarter of its normal size, it "CANNOT" be removed from below. It comes out towards the radiator and curves left and upwards. One very important part of the manual refers to removing the lower bolts first. This makes it much easier, Foolish old git I tried the other way first. Due to not possessing a vehicle lift it was impossible to remove the semi rigid tube from the turbo. this means finding another way to remove the top right bolt, imagination?

Due to clearance issues with the A/C piping it was decided to shorten the bottom right bolt by 8mm to avoid fouling the A/C piping.

The actual removal and replacement of the compressor took about 5 hours due to access and using a 10mm spanner one flat at a time plus serious swelling to one hand.

I understand now why it is said that NO mechanic will thank you for letting him due this job. 3 turned me down saying it was too complicated. Some of the !Removed! Ford/jag  tube clips had to be carefully cut off with a Dremel because there was no way to get to the ends.

Incidentally when the gas was removed also the Oil was removed, so the old compressor was empty.

Tomorrow- reinstall Heat exchanger, connect all rubber tubes install Fan and shroud and refill with coolant. If there is time go and get it regassed and loaded with Oil.

Maybe just maybe, I will have some cold air. Did the mod on the replacement compressor for low rev working.

[mrmike]

Having done this, I do not recommend anyone to try it unless you have a full lift. Apart from patience you will also need a full set of tube clip removal tools.

Small hands and more patience. Even the plastic block under the heat exchanger was a real ba%^&* to install with the heat exchanger. After 2 hours of fiddling I cut off

one corner of the plastic and did not use the 2 bolts. I used wide Tie Wraps to hold it all in place as I will be replacing it any way. You should try and con an Indie, just show him a few pages from 2662 to 2667  and say I would do it myself but a few things have come up.........................

Credit to Jaguar the plastic bits seem very strong, only problem left is the cover of the air filter being very difficult to fit correctly.

I have some pics if anyone is interested.

[mrmike]

Got it refilled with gas and Oil today, It is now a "COOL" Car.