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    [Maintenance case] BMW 520Li compressor clutch failure

    [Maintenance case] BMW 520Li compressor clutch failure Model: F18. Driving mileage: 3000km. Fault phenomenon: The user reports that the vehicle's air conditioning system is faulty. Sometimes, the cooling effect of the air conditioner suddenly fails during use. The hot air is blown out of the tuyere. The vehicle restarts to turn on the air conditioner after the vehicle is driven for a while or is turned off. The air conditioning cooling function returns to normal. Fault diagnosis: After picking up the vehicle, first verify the fault phenomenon reflected by the user, turn on the air conditioner at the idling state of the vehicle, adjust the setting to the maximum power cooling, and the air outlet can blow out very cool and cool wind. At this time, there is no problem with the cooling of the air conditioning system. When the vehicle is running at idle speed for about 30 minutes, it feels that the temperature of the air blown by the air conditioner is getting higher and higher. After a while, it feels completely hot. At this time, the observation from the engine compartment revealed that the electromagnetic clutch of the compressor was not engaged. Turn off the vehicle, wait for a while, start the vehicle again to turn on the air conditioner, and the cooling effect of the air conditioner returns to normal again. Connect the ISID for diagnostic test, read the fault related to the air conditioning system and store it as "8020C8 compressor clutch short circuit to ground". Check the detailed description of the fault code as shown in the table. Table 1 Fault code description Select the fault content to execute the test plan. For the detected function / component, the following fault data is stored: 8020C8 compressor clutch short circuit to ground. Before executing this test module, make sure that the following electrical components are free of any faults: regulating valve, air conditioning button, refrigerant pressure sensor, evaporator temperature sensor. Analyze the unprocessed existing fault code storage records and eliminate the fault. To do this, select and process related components in the following menu items. Air conditioner button Refrigerant pressure sensor Regulating valve Evaporator temperature sensor Electromagnetic clutch Select the measuring electromagnetic clutch and turn off the engine. During the measuring step, the compressor clutch will be controlled by diagnosis, and the control will be activated for 30s. Through the diagnosis and control of the compressor clutch, the crackling noise should be clearly heard. Test results can hear the crackling sound of the compressor clutch. Start the vehicle, turn on the air conditioner, and observe the cooling pressure value of the air conditioner through the diagnostic instrument. This pressure value should slowly increase when the cold air function is activated. The initial value of the pressure sensor is 700kPa, the actual pressure sensor value is 700kPa, and the actual pressure value has not increased. Next, measure the supply voltage of the compressor clutch connection adapter when the air conditioning compressor is working. The measurement must be made through pin 3 of the adapter interface and the grounding point in the vehicle. During the control of the refrigerant compressor through diagnosis, the engine is not allowed to run, and the refrigerant compressor is controlled by the cooling and heating air conditioning control module through diagnosis. The circuit diagram of the junction box control module controlling the compressor clutch is shown in Figure 1. The supply voltage of the measured compressor clutch should be approximately the value of the vehicle network voltage. Connect the adapter from the compressor clutch connection plug Y1 * 1B, and measure the voltage between pin 3 of the adapter interface and the vehicle ground. The measurement result is 12.2V, which is the vehicle's vehicle network voltage. It means that the junction box control module has no problem in controlling the power supply of the electromagnetic clutch of the compressor. Continue to carry out the test plan, measure the resistance of the compressor clutch, require disconnecting the bus terminals KL.15 and KL.R, and disconnect the wiring harness of the connection box control module from the adapter interface. Through the 3 feet of the adapter interface and the grounding point in the vehicle, the standard value range: 2.5 ~ 15Ω. The measurement results show that the compressor clutch resistance is 0.52Ω, which is no longer within the standard range. But it didn't take long to find a phenomenon, the measured resistance value was continuously rising until it rose to about 8Ω, and the resistance value returned to the normal range. At this time, start the vehicle, turn on the air conditioner, and the cooling function of the air conditioner returns to normal. Continue to observe the cooling effect of the vehicle and measure the resistance value of the compressor clutch. When the air conditioning system has no cooling effect, immediately measure the resistance value of the compressor clutch. The measurement result is approximately zero. The vehicle stalled, and after a while, the resistance value gradually increased again. This shows that the coil of the compressor clutch does have a short circuit at a certain temperature. Troubleshooting: Replace the compressor, add refrigeration oil in accordance with ISTA standard requirements, evacuate and add refrigerant. Run the replacement of the new compressor through the service function, and then observe the cooling effect of the vehicle for a long time. The cooling function of the vehicle has been normal. By calling the control module function, the key data of the air conditioning system is read. In the normal range, the electromagnetic clutch of the compressor is in working state, and the fault is eliminated.

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