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a/c compressor install problems

(Also listed in turbo site)

I bought a new Denso compressor for the a/c and verified the part number. After servicing the unit prior to install I started having issues with getting it to fit. I micrometered the mounts and found the mounting ears were 1 mm too wide so I carefully dressed them to snugly fit. Still after two days of effort, I still can't get the bolts to go in. There appeared to be some interference spots at the top so I filed them down and I still can't get the bolts to go in. Am I the only one who has encountered this or is it a common issue with compressor replacement?

I've gone over the parts diagrams and pictures and watched videos so I'm still at a loss for where the problem might be.

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3 944's, 2 Boxsters and one Caman S, and now one 951 turbo. Really miss the Cayman.

Some people try to turn back their "odometers." Not me. I want people to know 'why' I look this way. I've traveled a long way and some of the roads weren't paved.
Old 10-30-2019, 02:30 PM
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Did something on your car perhaps get bent due to hamfisting of the adjustment strut?

I had a car once, non-porsche, where I had to put a blunt point on a pivot bolt and cut a bit of thread into that to draw the accessory mount into alignment via hammer, swearing.
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Old 10-31-2019, 04:52 AM
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Nope. The old one was pretty tight fitting but it came out. After relieving the new one a tad it would slide in but for some reason it won't let me align the mount holes laterally. I think I'll get back at it with the condenser hose removed (to take the strain off) to see if that will help. It's been pretty hot around here but the weather's cooling finally so I'll give it another try.
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3 944's, 2 Boxsters and one Caman S, and now one 951 turbo. Really miss the Cayman.

Some people try to turn back their "odometers." Not me. I want people to know 'why' I look this way. I've traveled a long way and some of the roads weren't paved.
Old 11-01-2019, 12:00 PM
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You found your answer. Always mount the compressor with the manifold on, then attach the suction and discharge lines/hoses. Did you drain the oil out of the new compressor? Did you measure the oil in the old one?
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Last edited by mattdavis11; 11-01-2019 at 10:03 PM..
Old 11-01-2019, 10:01 PM
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I was thinking that very thing. Yes I followed all the proper procedures in readying the new compressor for install, including a new line to the condenser.
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3 944's, 2 Boxsters and one Caman S, and now one 951 turbo. Really miss the Cayman.

Some people try to turn back their "odometers." Not me. I want people to know 'why' I look this way. I've traveled a long way and some of the roads weren't paved.
Old 11-03-2019, 09:33 AM
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compressor install SOLVED

Pulled the hose off the compressor, used a mallet to tap the sleeve for the rear mounting bolt back so it didn't interfere with the bracket on the compressor. Finally was able to get it installed and replaced hose from compressor to condenser. That was a head scratcher.

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3 944's, 2 Boxsters and one Caman S, and now one 951 turbo. Really miss the Cayman.

Some people try to turn back their "odometers." Not me. I want people to know 'why' I look this way. I've traveled a long way and some of the roads weren't paved.
Old 11-09-2019, 09:18 PM
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