When it comes to servicing and replacing electric air conditioning compressors, the experts at MAHLE have the following advice

Electric air conditioning compressors used in electric and hybrid vehicles differ significantly from traditional belt-driven compressors.
MAHLE explains these compressors require specific handling and care to ensure optimal performance and to avoid costly repairs.

Key features of electric compressors
One of the main differences between electric compressors and traditional belt-driven models is that electric compressors are hermetically sealed.
Without a drive shaft, there is no risk of refrigerant leaking through shaft seals, which makes the system more reliable and efficient.
Inside the compressor, an electric motor drives the system. Since this motor comes into direct contact with refrigerant and compressor oil, it is crucial to use oil with insulating properties.
Using the wrong oil can lead to a short circuit if moisture enters the refrigerant circuit.
For this reason, MAHLE says nonhygroscopic oils like PAO multigrade oils are preferred because they do not absorb moisture from the air.
MAHLE recommends that you always follow the vehicle manufacturer’s specifications when selecting refrigerants and oils, warning that incorrect oil choices or irregular servicing can lead to system failures and reduced efficiency.
It also states regular air conditioning system services are crucial to ensure electric compressors run smoothly and safely.

Replacing electric compressors
Replacing an electric air conditioning compressor requires special care and should only be performed by technicians certified to work on high-voltage systems, says MAHLE.
Electric compressors don’t have an oil drain plug, which means you can’t adjust the oil level through the compressor itself.
Therefore, the entire air conditioning system must be flushed to remove any old oil before a new compressor is installed.
MAHLE explains this ensures the system is free from oil residues and prevents overfilling, which could damage the new compressor. Any components that cannot be flushed, such as the drier, must also be replaced, it says.
Additionally, many manufacturers use specialised software to safely commission a new compressor.
This software, accessed through a diagnostic tester, ensures a slow and steady start-up, preventing a sudden intake of oil that could cause damage, such as hydraulic shock.
By following these steps and adhering to manufacturer guidelines, MAHLE says you can ensure the efficient and safe operation of electric air conditioning compressors.

For more information on MAHLE e-compressors, please visit www.mahle-aftermarket.com or email sales.australia@mahle.com