Compressor, 10-Cylinder
Compressor, 10-Cylinder
• Compressor is driven via a toothed gear and an driveshaft - B -.
• Compressor bracket, removing from engine and installing.
• To remove the compressor on vehicles with a 10-cyl. FSI engine (Audi S6), the refrigerant circuit must be drained and then both refrigerant lines must be removed from the compressor. Refer to => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.
• On vehicles with a 10 cylinder TFSI engine (Audi RS6), the refrigerant circuit must be emptied and the engine removed to remove the compressor.
• The compressor installed at the factory for a 10-cyl. TFSI engine (Audi RS6) has a lower quantity of refrigerant oil than the compressor for the 10-cyl. FSI engine (Audi S6) due to the different testing procedures for the engines (the compressors at present differ only in part number and quantity of refrigerant oil, see also the compressor label). When adjusting the total oil quantity in the refrigerant circuit for a 10-cyl. TFSI engine (Audi RS6) at the factory, the oil quantity that was reduced in the compressor has to be filled somewhere else in the refrigerant circuit (only necessary at customer service if a new compressor with the reduced oil quantity is installed).
10-Cylinder FSI
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Used Oil Collection and Extraction Device (V.A.G 1782)
• Hose clamp pliers (V.A.G 1921)
• Spring type clip pliers (VAS 5024A)
• Engine Support Supplement Set (T40093)
Removing
- Discharge refrigerant circuit.
- Drain coolant.
- Remove engine cover at front - 1 - and at rear - 2 - - arrows -.
- Remove left air filter housing.
- Extract power steering fluid from reservoir using old oil collecting and extracting device (VAG 1782).
- Remove bolts - 2 - and - 3 -.
- Pull guide tube for oil dipstick off upward - arrow -.
• Ignore - 1 - and - item 4 -.
- Remove bolt - arrow - for left engine mount.
- Pull off rubber seal - 1 - and remove plenum chamber cover - 2 -.
- Secure Engine Support Bridge (10-222 A) with supports (T40093/1) and (T40093/2) to suspension strut domes.
• The supports are marked for the left and right vehicle sides.
- Secure spindles of Engine Support Bridge (10-222 A) to rear engine lifting eyelets.
- Pre-tension engine using spindles on engine support bridge.
- Uniformly unscrew the left and right bolts and nuts - 1 - 5 -.
- Remove anti-roll bar with transverse beam.
- Disconnect electrical harness connector - 1 - (mark connector to avoid possible interchange).
- Remove bolts - 2, 3, 4 - and remove left engine console with engine mount.
- Disconnect bottom left coolant hose - arrow - from radiator.
- Disconnect electrical harness connector - arrow - at engine coolant temperature sensor on radiator.
- Remove coolant hose - 2 - from coolant thermostat housing at bottom.
- Remove bolts - arrows -.
- Remove coolant thermostat housing and remove coolant hose - 1 - from coolant thermostat housing at top.
• Do not bend, kink or stretch lines or hoses as refrigerant lines and refrigerant hoses may be damaged.
- Remove screws - 1 - and - 2 -.
- Disconnect refrigerant lines from A/C compressor.
• Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture).
- Remove coolant hose - arrows - and place coolant pipe upward.
• Place a rag beneath the separation point to catch escaping hydraulic fluid.
- Disconnect hydraulic hose - arrow - from line at left longitudinal member.
- Remove bolts - arrows - and remove left engine support.
- Counterhold compressor driveshaft - A - using an open-end wrench and turn compressor drive unit - B - in - direction of arrow C -.
• Compressor driveshaft - A - must not be turned.
• Compressor driveshaft - A - can be slid into drive wheel through boot - E - after loosening threaded connection.
- Disconnect electrical harness connector - 1 - to A/C Compressor Regulator Valve (N280) (mark the connector to prevent risk of interchange with connector to engine mount).
- Remove bolts - arrows -.
- Remove A/C compressor.
Installing
Installation is done is reverse order, observe the following:
• Secure all hose connections with hose clamps used in series production.
• An uncertain quantity of refrigerant oil remains in a removed compressor, therefore observe notes for replacing the compressor.
- Install compressor driveshaft - A - (into drive wheel of engine) and check seating as well as corresponding boot - E -. Refer to => [ Compressor Drive Shaft, Loosening and Tightening ] Compressor Drive Shaft, Loosening and Tightening.
- Thoroughly clean contact surfaces at bracket (and contact surfaces at compressor), if necessary remove bushings - F - from compressor bracket or compressor.
- Check connections of compressor and of refrigerant lines for damage or soiling. Refer to => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.
- Make sure bushings - F - are inserted in A/C compressor or in bracket.
• Ensure bushings - F - are properly seated and contact surfaces are clean. Sockets installed incorrectly and dirty or damaged contact surfaces can lead to alignment irregularities between the compressor and engine. Alignment irregularities over operating time lead to damage to input shaft or compressor.
- Attach compressor to bracket with bolts - D - and washers - E - (tightening torque 25 Nm).
- Replace sealing rings - B - and - C - => [ Refrigerant Circuit O-Ring Seals ] Refrigerant Circuit O-Ring Seals.
- Attach the refrigerant lines to the compressor => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor (Bolts - A - tightening specification: 25 Nm), dimensions of o-rings - B - and - C - and additional information => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.
- Before screwing in driveshaft, rotate compressor 10 rotations by hand (after installing) via compressor drive unit - B - in direction of arrow - C - (to prevent damage to compressor with first switch-on).
• Rotating forces refrigerant oil out of the compression chamber if it has accumulated there in the removed compressor or after adding fresh refrigerant oil (e.g. after flushing the refrigerant circuit).
- Tighten driveshaft, hold compressor driveshaft - A - in place using open-end wrench and turn compressor drive unit - B - in direction of arrow - D - (tightening torque 60 Nm).
• Do not turn the driveshaft - A -.
• After installing driveshaft - A -, check installation position of boot - E -.
• A clamp on the power steering pump flange prevents the boot - E - from slipping.
- Install engine supports.
- Install coolant regulator housing.
- Install engine mount console.
- Install stabilizer.
- Install left air filter housing.
- Fill hydraulic fluid into power steering reservoir.
- Re-install remaining components removed.
- Empty and fill refrigerant circuit.
- Fill coolant and bleed coolant circuit.
- Check the DTC memory for the Climatronic Control Module (J255) A/C control head and erase any faults displayed if necessary.
- Operate the A/C system after filling the refrigerant circuit. Refer to => [ A/C System, Operating after Filling Refrigerant Circuit ] A/C System, Operating after Filling Refrigerant Circuit.
10-Cylinder TFSI
• In vehicles with an exhaust gas turbocharger, the left engine support can be removed only if the exhaust manifold and turbocharger are removed. For this reason, the engine has to be removed to remove and install the compressor.
Removing
- Discharge refrigerant circuit.
• Engine / gear unit has been removed and placed on the Scissors Lift (VAS 6131 A)
• To enable the engine to be removed, bolts - 1 - and - 2 - have to be removed, and the refrigerant lines have to be disconnected from the compressor => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor (the refrigerant lines remain in the vehicle).
• Do not bend, kink or stretch lines or hoses as refrigerant lines and refrigerant hoses may be damaged.
• Seal open lines and connections at the compressor as well as the refrigerant lines with suitable caps or clean plugs (to prevent dirt and moisture from entering).
- Remove the left exhaust gas turbocharger.
• Mark electrical connector - 1 - to the A/C Compressor Regulator Valve (N280) and to the Left Electrohydraulic Engine Mount Solenoid Valve (N144) prior to disconnecting (risk of interchange).
- Disconnect the electrical connector - 3 - on the left electrohydraulic engine mount solenoid valve (N144) and lay the electric cable to the side.
- Remove the bolts - arrows - and remove the engine support with the engine mount and console.
• Disregard - item 1, 2 -.
- Counterhold compressor driveshaft - A - using an open-end wrench and turn compressor drive unit - B - in - direction of arrow C -.
• Compressor driveshaft - A - must not be turned.
• Compressor driveshaft - A - can be slid into drive wheel through boot - E - after loosening threaded connection.
- Remove the electrical connector - 1 - for the A/C compressor regulator valve (N280) from the bracket and disconnect it.
- Remove bolts - arrows -.
- Remove A/C compressor.
Installing
Installation is done is reverse order, observe the following:
- Remove the alignment sleeves - F - from the compressor if necessary.
- Thoroughly clean the contact surfaces on the compressor and bracket.
- Install the alignment sleeves - F - in the compressor.
• Make sure the alignment sleeves are seated correctly and the contact surfaces are clean. Alignment sleeves that are installed incorrectly and dirty or damaged contact surfaces can lead to alignment irregularities between the compressor and engine. Alignment irregularities over operating time lead to damage to input shaft or compressor.
• There is an unspecified amount of refrigerant oil in the removed compressor so follow the information on replacing the compressor.
- Check the compressor and refrigerant line connections for damage and dirt => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.
- If necessary, install the compressor driveshaft - A - (into the engine drive wheel) and check the seating of the driveshaft and the corresponding grommet - E - => [ Compressor Drive Shaft, Loosening and Tightening ] Compressor Drive Shaft, Loosening and Tightening.
- Attach the compressor to bracket with bolts - D - (and washers - E -).
- Tighten bolts - arrows -.
• Tightening specification: 25 Nm.
- Connect electrical connector - 1 - on A/C Compressor Regulator Valve (N280) (note the identification marking that was added).
- Before installing compressor driveshaft - A -, install compressor drive unit - B - on compressor by rotating 10 turns by hand in - direction of arrow C - in order to avoid damage to compressor when switching on for the first time.
• By rotating, refrigerant oil which has accumulated in the compressor compression chamber in the removed compressor or after adding fresh refrigerant oil (e.g. after irrigating the refrigerant circuit) is forced out of the compression chamber.
- Counterhold compressor driveshaft - A - using an open-end wrench and turn compressor drive unit - B - in - direction of arrow D -.
- Tighten the driveshaft.
• Tightening specification: 60 Nm.
• Compressor driveshaft - A - must not be turned when tightening.
• After installing, check installation position of grommet - E - on drive wheel.
• After installing the driveshaft - A -, check the boot - E - installation position.
• The grommet - E - is secured against slipping by the clamp used in series production on the power steering pump flange.
- Install engine support with left engine mount.
- Install the exhaust manifold and left exhaust gas turbocharger.
Install the engine / gear unit.
- Install the refrigerant lines on the compressor => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.
• Dimensions of O-ring seals - B - and - C - as well as additional information => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.
- Re-install remaining components removed.
- Empty and fill refrigerant circuit.
- Fill coolant and bleed coolant circuit.
- Check the DTC memory for the Climatronic Control Module (J255) A/C control head and erase any faults displayed if necessary => Vehicle Diagnosis, Testing and Information System VAS 5051.
- Operate the A/C system after filling the refrigerant circuit. Refer to => [ A/C System, Operating after Filling Refrigerant Circuit ] A/C System, Operating after Filling Refrigerant Circuit.