Easy Aircon Repair

Forrest · Aug 2nd, 2022, 15:57

I have had a problem for a couple of years with my 1997 940 CD with automatic climate control whereby the aircon would work well for about 10-30 minutes and then cutout, just blowing warm air. The problem seemed worse in hotter weather, but maybe just more noticeable. The refrigerant gas had been recharged and no leaks identified but the problem persisted. After cooling down it would work normally for a further period of 10-30 minutes.

It transpires the problem was due to an excessive clutch gap on the Zexel compressor. There seems to be a lot of information about this fault relating to other Volvos of the period but I don't recall seeing it discussed here.

The guide I used for fixing it is here, but of course access is very much easier on the 940.

https://blog.fcpeuro.com/how-to-fix-...-in-a-volvo-p1

I bought this puller kit to remove the clutch without damaging it.

https://www.ebay.co.uk/itm/174966947811

My clutch only had two shims fitted. I started with a gap of 0.9mm and brought this down to 0.4 by removing one of the shims.

The aircon now works normally again. This is one of the easiest but most satisfying fixes I've done in a while. I thought I'd share in case it helps anyone else. Bear in mind that the most likely cause of the aircon compressor cutting out is the low pressure switch if the refrigerant is low; so be sure to check that first.

Aug 2nd, 2022, 15:57	#1
Forrest VOC Member Last Online: Yesterday 23:57 Join Date: Feb 2008 Location: Gloucester	Easy Aircon Repair I have had a problem for a couple of years with my 1997 940 CD with automatic climate control whereby the aircon would work well for about 10-30 minutes and then cutout, just blowing warm air. The problem seemed worse in hotter weather, but maybe just more noticeable. The refrigerant gas had been recharged and no leaks identified but the problem persisted. After cooling down it would work normally for a further period of 10-30 minutes. It transpires the problem was due to an excessive clutch gap on the Zexel compressor. There seems to be a lot of information about this fault relating to other Volvos of the period but I don't recall seeing it discussed here. The guide I used for fixing it is here, but of course access is very much easier on the 940. https://blog.fcpeuro.com/how-to-fix-...-in-a-volvo-p1 I bought this puller kit to remove the clutch without damaging it. https://www.ebay.co.uk/itm/174966947811 My clutch only had two shims fitted. I started with a gap of 0.9mm and brought this down to 0.4 by removing one of the shims. The aircon now works normally again. This is one of the easiest but most satisfying fixes I've done in a while. I thought I'd share in case it helps anyone else. Bear in mind that the most likely cause of the aircon compressor cutting out is the low pressure switch if the refrigerant is low; so be sure to check that first.

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