Compressor, 8-Cylinder
Compressor, 8-Cylinder
Removing
- Drain the refrigerant circuit.
- Extract the hydraulic oil for power steering from the reservoir with a flexible oil extraction probe (V.A.G 1358/A).
CAUTION!
When opening the expansion tank, hot steam or hot coolant can escape. Cover the cap with a cloth and open carefully.
- Open the cap of the coolant expansion tank.
- Unscrew the left front wheel.
- Release quick-release couplings - 1 -, unscrew screws - 2 -, and remove the noise insulation.
- Remove the front bumper.
- Remove the left air guide - arrow - before the auxiliary cooler.
- Remove the right air guide - arrow - before the auxiliary cooler.
- Place a drip tray (V.A.G 1306) underneath the engine.
- Unscrew the drain plug - arrow - on the coolant regulator housing and drain the coolant from the engine.
- Remove the bottom coolant hose from the radiator - arrow - and drain the remaining coolant.
- Place an oil collection container under the hydraulic lines to the rear cooling coil.
- Disconnect the hydraulic lines to the rear cooling coil on the lock carrier - arrows -.
- Remove right cover - 1 - in the engine compartment.
- Detach the evaporative emission (EVAP) canister purge regulator valve (N80) - 1 - on the air guide.
- Remove bolts - arrows -.
- Remove air duct - 2 -.
- Disconnect the upper coolant hose - arrow - from the radiator.
- Remove cover - 1 - on the left in the engine compartment.
- Remove electrical connectors - 1 - and - 2 - from the bracket and disconnect them.
- Expose the lines to the lock carrier.
- Disconnect the electrical connector - arrow - for the headlamp on both sides of the vehicle.
- Disconnect the electrical connector - arrow - for the airbag sensors on the left and right on the lock carrier.
- Expose the lines.
- Remove the control cable for the front flap on the lock carrier.
- Disconnect the electrical connector - arrow - for the right fan.
- Unscrew the air guides on the left and right on the radiator - arrows -.
CAUTION!
Do not bend or stretch lines or hoses since the condenser and refrigerant lines/hoses may be damaged.
- Unscrew the refrigerant line - arrow - to the A/C compressor.
- Unscrew the refrigerant line - arrow - to the A/C system evaporator.
- Remove the screws - arrows - on the lock carrier on the left and right.
- Remove the hood seal on the lock carrier and on the fender edges.
- Unscrew the screws on the shock absorbers - arrows - on the left and right.
• A second technician is needed to remove the lock carrier.
- Remove the lock carrier and set it down in a secure manner.
- Remove the rear engine cover - arrows -.
- Place the engine support bridge (10 - 222 A) on the bolted flanges of the fender.
- Attach the hook of the engine support bridge to the engine lifting eye.
- Slightly pre-tension the engine with the spindle on the engine support bridge, do not lift.
- Remove the coolant hoses at the locations marked with arrows.
- Remove the coolant hose at the coolant regulator housing - arrow -.
CAUTION!
Do not bend or kink the refrigerant lines.
- Unscrew the retaining clamp - arrow - for the refrigerant line on the bracket on the right.
- Remove the bracket on the left for the refrigerant line - arrow -.
- Remove bolts - 1 - and - 2 -.
- Detach the refrigerant lines from the A/C compressor and seal the open connections. Refer to => [ Refrigerant Lines, Disconnecting and Connecting from Compressor ] Refrigerant Lines, Disconnecting and Connecting From Compressor.
- Remove nuts - 1... 4 - for the stabilizer mount on the left and right.
- Remove the nut - 2 -.
- Remove screws - 1 - and - 3 - and remove the engine bracket.
- Disconnect electrical connection - 1 - on the engine bracket on the left.
- Remove nuts - 2 - and remove the engine mount.
• Shown in the figure with the engine removed.
- Remove screws - 1 - and - 2 -.
• To prevent oil leakage, the hose - arrow - remains connected to the power steering.
- Unscrew the guide tube for the oil dipstick on the cylinder head - arrow - and remove it in an upward direction.
- Remove the engine support on the left - arrows -.
- Hold compressor driveshaft - A - in place using an open-end wrench and turn compressor drive unit - B - in direction of arrow - C -.
• Do not turn the driveshaft - A -.
• Driveshaft - A - can be slid into drive wheel through the boot - E - after loosening threaded connection.
- Disconnect the 2-pin harness connector to the A/C compressor regulator valve (N280).
- Remove screws - D - (tightening torque of 25 Nm).
- Remove the compressor in a forward direction.
- Remove bushings - F - from compressor if necessary.
Installing
Before installing compressor. Refer to => Heating and Air Conditioning Heating and Air Conditioning
• There is an unspecified amount of refrigerant oil in the removed compressor so follow the information on replacing the compressor.
- Install the compressor drive shaft (into the drive wheel of the engine) and check the seating as well as the corresponding grommet. Refer to => [ Compressor Drive Shaft ] Compressor Drive Shaft
- Remove bushings - C - from compressor bracket if necessary.
- Thoroughly clean contact surfaces - A - and - B - on bracket (and contact surfaces on compressor).
- Install bushings - C - into compressor bracket.
• Ensure that bushings - C - have proper seating 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.
- Check the type of seal at the connections and the refrigerant lines. These must be designed for the same type of seal. Refer to => [ Refrigerant Line to Component Connections ] Refrigerant Circuit, Servicing
- Attach compressor to bracket with bolts - D - and washers - E - (tightening torque 25 Nm).
- Install the refrigerant lines on the compressor (tightening torque of screws - A - 10 Nm for screws with thread M6 and 25 Nm for screws with thread M8), dimensions of the O-ring seals - B - and - C - as well as additional information. Refer to => [ Refrigerant Lines, Disconnecting and Connecting from Compressor ] Refrigerant Lines, Disconnecting and Connecting From Compressor.
- After installing a new compressor or filling the compressor with new refrigerant oil (e.g. after flushing the refrigerant circuit) manually rotate the compressor via compressor drive unit - B - in the direction of arrow - C - prior to tightening the drive shaft approx. 10 revolutions in order to prevent damage to the compressor.
- 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 -.
• Socket - E - is secured against slipping off by a clamp on power steering pump (introduction of clamp in production as of model year 2005, install clamp as a retrofit if necessary).
- Re-install remaining components removed.
- Empty and fill refrigerant circuit.
- Run the A/C system after installing the compressor. Refer to => [ Running A/C System After Installing Compressor ] Running A/C System After Installing Compressor