87404-2A/C compressor, replace

Excluding draining and refilling of refrigerant

Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

WARNING
Risk of serious injury.
Carelessness during pressing can cause crushing injuries. There is also a risk that the
components being pressed slip away and cause injury to individuals in the surrounding
area.
▶ Exercise caution during pressing. Use safety goggles.
Special tools
88890148

1 Set the key in position 0.

2 Apply the handbrake.

3 Position the wheel chocks.
4 This step contains 2 alternatives.
Select one of the valid alternatives below.
Alternative 1 / 2
▶ Turn off the main switch.
Alternative 2 / 2
Conditions
● If the vehicle is equipped with ADR (European Agreement Concerning the International
Carriage of Dangerous Goods by Road).
▶ Turn off the main switch.
5 Open the front panel.
 CAUTION
Risk of material damage.
Damage may occur to the cab.
▶ Make sure that there is adequate space in front of the vehicle before tilting the cab.

WARNING
Risk of serious injury.
A cab that is not tilted to the end position constitutes a safety risk.
▶ Always tilt the cab to the end position. Never perform any work under the cab before it
 has been tilted to the end position.
6 Tilt the cab.

7 Release the belt tensioner.

8 Install the screw.
Note

To lock the tensioner.

9 Disengage the belt.
1 This step contains 2 alternatives.
0 Select one of the valid alternatives below.
Alternative 1 / 2

CAUTION
Risk of material damage.
The cables can be damaged by sharp tools.
▶ Take care when removing the cable ties.
▶ Remov
e the
 cable
ties.

▶ Perform this procedure when the condition below is met.

Conditions
● If the alternator has a ground cable.
▶ Remove the nut.
▶ Disconnect the cable.
▶ Release the lock.
▶ Disconnect the connector.
▶ Remove the cap.
▶ Remove the nut.
▶ Disconnect the cable.
▶ Remove the screws and nuts.
▶ Remove the alternator.
Alternative 2 / 2

CAUTION
Risk of material damage.
The cables can be damaged by sharp tools.
▶ Take care when removing the cable ties.
▶ Remov
e the
cable
ties.
▶ Perform this procedure when the condition below is met.
Conditions
● If the alternator has a ground cable.
▶ Remove the nut.
▶ Disconnect the cable.
▶ Release the lock.
▶ Disconnect the connector.
▶ Remove the cap.
▶ Remove the nut.
▶ Disconnect the cable.
▶ Remove the screws and nuts.
▶ Remove the alternator.
11 Disconnect the connector.
12 Remove the screw.
13 Remove the hose.
14 Remove the screw.
15 Remove the hose.
16 Remove the screws.
17 Remove the compressor.
18 Remove the O-rings.
19 Install the compressor.
20 Install the screws.
Tightening torque
Compressor, screw 24 ±4 Nm
Required material
TORQUE WRENCH 88890148
21 Install the O-rings.
22 Lubricate the O-rings.
Note

Use recommended oil.

23 Install the hose.
24 Install the screw.
Tightening torque
Pipe flange, screw 12 ±2 Nm
Required material
TORQUE WRENCH 88890148
25 Install the hose.
26 Install the screw.
Tightening torque
Pipe flange, screw 12 ±2 Nm
Required material
TORQUE WRENCH 88890148
27 Connect the connector.
2 This step contains 2 alternatives.
8 Select one of the valid alternatives below.
Alternative 1 / 2
▶ Clean the contact surfaces on the mounting brackets and the alternator.
▶ Install the alternator.
Note

Ensure that no oil, grease, paint or other dirt exists in between the contact surface of
mounting brackets and alternator.
▶ Install the screws and nuts.
▶
Torque tighten the screws.
Tightening torque
Alternator,upper fixing, screw M10×50
48 ±8 Nm
Tightening torque
Alternator, lower fixing, screw 85 ±15 Nm
Required material
Tightening torque
TORQUE WRENCH 88890148

WARNING

Risk of serious injury and material damage.

Risk of short-circuit.
▶ Cover electrical contacts with the protection provided.

▶
Connect the cable.

▶ Install the nut.

▶ Torque tighten the nut.
 Tightening torque
Alternator, positive terminal, nut 12 ±2 Nm

▶ Install the cap.

▶ Connect the connector.
▶ Lock the connector.
▶ Perform this procedure when the condition below is met.
Conditions
● If the alternator has a ground cable.
▶ Connect the cable.
▶ Install the nut.
▶ Torque tighten the nut.
Tightening torque
Alternator, negative terminal, nut 10 ±1.5 Nm
Required material
TORQUE WRENCH 88890148
▶ Install the cable ties.
Alternative 2 / 2
▶ Clean the contact surfaces on the mounting brackets and the alternator.
▶ Install the alternator.
Note

Ensure that no oil, grease, paint or other dirt exists in between the contact surface of
mounting brackets and alternator.
▶ Install the screws and nuts.
▶ Torque tighten the screws.
Tightening torque
Alternator,upper fixing, screw M10×50
48 ±8 Nm
Tightening torque
Alternator, lower fixing, screw 85 ±15 Nm
Required material
TORQUE WRENCH 88890148
▶ Connect the cable.
▶ Install the nut.
▶ Torque tighten the nut.
Tightening torque
Alternator, positive terminal, nut 12 ±2 Nm
▶ Install the cap.
▶ Connect the connector.
▶ Lock the connector.
▶ Perform this procedure when the condition below is met.
Conditions
● If the alternator has a ground cable.
▶ Connect the cable.
▶ Install the nut.
▶ Torque tighten the nut.
Tightening torque
Alternator, negative terminal, nut 10 ±1.5 Nm
Required material
TORQUE WRENCH 88890148
▶ Install the cable ties.
29 Position the belt on the pulley.
30 Remove the screw.
31
Release the belt tensioner.
Note

Ensure that the belt seats correctly in the grooves.

 WARNING

Risk of serious injury.

A cab that is not tilted to the end position constitutes a safety risk.
▶ Always tilt the cab to the end position. Never perform any work under the cab before it
has been tilted to the end position.
32
Lower the cab.

33 Close the front panel.