Bosch ACS 653 Repair Instruction page 95

ACS 653, ACS 663 Service Manual
Repairing or Replacing a Solenoid
WARNING: Disconnect the unit from
the power source before beginning
service work. Incorrect use or
connections can cause electrical
shock.
WARNING: Wear safety goggles
when working with refrigerants.
Refrigerants can cause eye injury.
WARNING: Use extreme caution when
disconnecting hoses. Pressurized
refrigerant may be present in hoses.
Point hoses away from you and
anyone nearby.
Instructions
These instructions outline the steps to repair
solenoids found throughout the unit.
Removing Solenoid
1. Depressurize the unit (select "AC unit
emptying" function in the service menu).
2. Disconnect the unit from the power source.
3. Remove the front plastic cover and service
hoses.
4. Open the service rear door.
5. Remove the rear cover (above the service
door) by pushing it up and extract it by
pulling it out.
6. Disconnect the two wires connected to the
solenoid being repaired or replaced.
7. Remove the fastener holding the coil on the
solenoid, and remove the coil.
NOTE: Once the nut and coil on top has been
remove, a special tool (14 mm stud remover)
has to be used to dismount the plunger
(only for new solenoid valves p/n SP00101437).
8. Remove the solenoid assembly.
9. Check the manifold block for any debris
before installing a repaired or replacement
solenoid.
Robert Bosch GmbH
Plumbing and Mechanical
Installing Solenoid
1. Lubricate the O-rings and threads on the
new solenoid assembly.
2. Install the repaired or replacement solenoid
assembly and hand tighten.
NOTE: Once the nut and coil on top has been
remove, a special tool (14 mm stud remover)
has to be used to dismount the plunger
(only for new solenoid valves p/n SP00101437).
3. Using a torque wrench, torque the solenoid
assembly to 9 Nm (80 in-lb).
4. Install the coil on the solenoid assembly,
and secure with the fastener holding the
coil in place.
5. Using a torque wrench, torque the coil
retaining bolt to 4 Nm (35 in-lb).
6. Reconnect the wires that were disconnected
earlier when removing the faulty solenoid
assembly.
7. Insert the rear cover so that the 4 holes on
the sides the cover fit into the 4 clips on the
machine. Push down to hook the rear cover.
8. Close the service rear door.
9. Reinstall the plastic frontal cover.
10. Attach the outside high- (red) and low-side
(blue) service hoses. Tighten at 7.9 Nm
torque.
11. Connect the unit to the power source,
perform a function test, and check for any
leaks.
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SP00D00624 2021-04-08