Compressor, Removing and Installing
Compressor, Removing And Installing (vehicles With 8 Cyl. Engine)
Removing (compressor driven via a shaft)
- Discharge refrigerant circuit Refrigerant R134a - Servicing.
- Use flexible oil extractor V.A.G 1358/A to draw off power steering hydraulic fluid from
CAUTION: Hot vapor or hot coolant may escape on opening reservoir. Cover cap with cloth and open carefully.
- Loosen cap of coolant reservoir.
- Unbolt front left wheel.
- Loosen quick-release fasteners - 1 - , screw out bolts - 2 - and remove noise insulation.
- Remove front bumper.
- Remove left air guide - arrow - in front of auxiliary cooler.
- Remove right air guide - arrow - in front of auxiliary cooler.
- Place drip tray V.A.G 1306 beneath engine.
- Remove drain plug - arrow - at housing for thermostat and drain off coolant at engine.
- Remove coolant hose at bottom of radiator - arrow - and drain off remaining coolant.
- Place oil drip tray beneath hydraulic lines to rear cooling line.
- Disconnect hydraulic lines to rear cooling line at lock carrier - arrows -.
- Remove cover - 1 - on right of engine compartment.
- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - at air guide.
- Remove bolts - arrows -.
- Remove air guide - 2 -.
- Remove coolant hose at top - arrow - of radiator.
- Remove cover - 1 - on left of engine compartment.
- Remove connectors - 1 - and - 2 - from bracket and disconnect.
- Expose bare wires to lock carrier.
- Disconnect connector - arrow - for headlights on both sides of vehicle.
- Disconnect connector - arrow - for airbag sensors on left and right of lock carrier.
- Expose bare wires.
- Remove hood cable at lock carrier.
- Disconnect connector - arrow - for fan on right.
- Unbolt air guides on left and right of radiator - arrows -.
NOTE: To avoid damaging condenser and refrigerant lines/hoses, make sure lines and hoses are not strained, kinked or bent.
- Unbolt refrigerant line - arrow - to air conditioner compressor.
- Unbolt refrigerant line - arrow - to air conditioner evaporator.
- Remove bolts - arrows - at lock carrier on left and right.
- Pull off hood seal at lock carrier and wing flanges.
- Remove bolts at impact absorbers - arrows - on left and right.
NOTE: A second technician is required to remove the lock carrier.
- Remove lock carrier and set down such that it cannot fall over.
- Remove rear engine cover - arrows
- Place support bar 10 - 222 A on wing mounting flanges.
- Engage hook of support bar in engine lifting eye.
- Use spindle of support bar to slightly pre-tension engine (do not raise).
- Remove coolant hoses at locations marked with arrows.
- Remove coolant hose at housing for thermostat - arrow
CAUTION: Take care not to kink or bend refrigerant lines.
- Unbolt retaining clip - arrow - for refrigerant line at bracket on right.
- Unbolt left bracket for refrigerant line - arrows -.
- Remove bolts - 1 - and - 2 -.
- Remove refrigerant lines from air conditioner compressor and seal open connections.
- Unbolt nuts -1 to 4. for anti-roll bar mount on left and right.
- Unbolt nut - 2 -
- Remove bolts - 1 - and - 3 - and remove engine bracket on left.
- Disconnect connector - 1 - at engine mounting on left.
- Unbolt nut - 2 - and remove engine mounting.
NOTE: Shown with engine removed in illustration.
- Remove bolts - 1 - and - 2 -.
NOTE: To stop fluid escaping, leave hose - arrow - connected to power steering.
- Unbolt guide tube for dipstick at cylinder head - arrow - and lift it off.
- Remove left engine support - arrows
- Use open-ended wrench to hold compressor drive shaft - A - in position and turn compressor drive unit - B - in direction of arrow - C -.
NOTE:
- Drive shaft -A- must not be turned.
- After loosening threaded connection, drive shaft -A- can be pushed through socket - E- into drive pinion.
- Disconnect 2-pin connector to A/C Compressor Regulator Valve N280.
- Remove bolts - D - (tightening torque 25 Nm).
- Remove compressor towards front
- If necessary, remove bushings - F - from compressor.
Installing
Before installing compressor Refrigerant R134a - Servicing
NOTE: The compressor removed contains an indeterminate amount of refrigerant oil. Attention is therefore to be paid to notes on compressor replacement Refrigerant R134a - Servicing.
- Install compressor drive shaft (in drive pinion) and check both proper attachment and corresponding socket.
- If necessary, remove bushings - C - from compressor bracket.
- Thoroughly clean contact surfaces - A - and - B - at bracket (as well as contact surfaces at compressor).
- Fit bushings - C - in compressor bracket.
NOTE: Pay attention to correct positioning of bushings - C- as well as clean contact surfaces. Incorrectly installed bushings or dirty/damaged contact surfaces could lead to misalignment between compressor and engine. In the course of operation, misalignment results in drive shaft or compressor damage.
- Check type of seal at connections and refrigerant lines (must be designed for same type of seal).
- Install compressor with bolts - D - (and washers - E -) to bracket (tightening torque 25 Nm).
- Install refrigerant lines to compressor (tightening torque of bolts - A - 25 Nm). For dimensions of O-rings - B - and - C and further information.
- After installation of a new compressor or after adding fresh refrigerant oil to compressor (e.g. after blowing out refrigerant circuit), give compressor approx. 10 turns by hand by way of compressor drive unit - B - in direction of arrow - C - before tightening drive shaft so as to avoid compressor damage.
- Tighten drive shaft. Use open-ended wrench to hold compressor drive shaft - A - in position and turn compressor drive unit - B - in direction of arrow - D - (tightening torque 60 Nm).
NOTE:
- Drive shaft -A- must not be turned.
- After installing drive shaft -A-, check installation position of socket - E-.
- Reinstall remaining components removed.
- Evacuate and fill refrigerant circuit. Refrigerant R134a - Servicing
- Start up air conditioner after mounting compressor.