S5

A/C Compressor

Special tools, testers and auxiliary items required

• Engine Support Bridge (10- 222 A)

• Engine Support Supplement Set (T40093)

• Engine And Transmission Lifter (V.A.G 1383 A)

Removing

- Turn the front wheels so that they are straight.

- Switch off the ignition.

Danger of destroying electrical components.

• Observe the steps when disconnect the battery.

- Disconnect the battery.

- Remove the engine cover - arrows -.






- Drain the refrigerant circuit.

• Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5).

- Disconnect the coolant hose - 3 - from the coolant overflow reservoir.






- Remove the bolts - arrows - and move the coolant overflow reservoir with the hoses still connected - 1 - and - 2 - to the side.

- Drain the coolant.

- Remove plenum chamber front wall - A -.






- Disconnect the upper coolant hose - right arrow - from the engine.






• This coolant hose is removed with the coolant pipe.

- Remove the screw - 2 -.

- Remove the bolt - arrows -.






- Remove the guide tube - 1 - for the oil dipstick from the upper part of the oil pan.

- Install the (10- 222 A) with adapters (T40093/6) on the left and right suspension strut domes as shown in the illustration.






- Mount the spindles (10- 222 A /11) on the engine lifting eyes.

- Pretension the engine with the spindles slightly.

- Remove the left and right front wheels.

- Remove the left and right wheelhouse liners.

- Remove the left and right drive axle from the transmission shaft.

- Remove the bolt - arrow - for the power steering hydraulic oil pressure line.






Danger of damaging the airbag spring.

• Disconnect the joint from the steering gear only with the front wheels in the straight ahead position.

• Do not change the position of the steering and the steering gear; secure the steering wheel with tape if necessary.

- Remove bolt - arrow - and the steering intermediate shaft from the steering gear and push them upward.






- Remove the CV joint from the steering gear and push it all the way up.

- Disconnect the vacuum hose - 1 - and free up the power steering hydraulic fluid hose - arrow - on the bracket.






- Remove the nuts - 2 - and remove the vacuum reservoir.

- Disconnect the connector - 1 - on the steering gear and free it up.






• Disregard - item 2 -.

- Free up the left power steering hydraulic oil hose on the subframe.

- Free up the wires on the right side of the subframe.

- Disconnect the ground wires - arrow - from the right longitudinal member.






- Remove the left and right bolts - 1 - and nuts - 3 - and the Lock Carrier Braces - 2 -.






- Disconnect the electrical connector on the Left Front Level Control System Sensor (G78) and free up the electric line - arrow -.






- Disconnect the electrical connector - 3 - for the Left Electro-Hydraulic Engine Mount Solenoid Valve (N144).






- Remove the bolt - 4 - for the left engine mount.

• Disregard - item 1, 2 - and - arrows -.

- Disconnect the electrical connector - 2 - for the Right Electro-Hydraulic Engine Mount Solenoid Valve (N145).






- Remove the engine mount bolt. Refer to - 1 -.

• Disregard - item 3, 4 - and - arrows -.

Danger of accident if the subframe is not secured.

• Remove the subframe bolts only when the subframe is supported.

- Support the subframe using the Engine-/Gearbox Jack (V.A.G 1383 A) as shown in the illustration.






- Remove the left and right stabilizer bolts - 3 -.






- Remove the left and right nuts - 1 - and the suspension strut bolts - 2 -.

- Remove the left and right bolts - 1... 3 - in stages.






Danger of damaging chassis components.

• If the vehicle must be placed on its wheel, then the complete subframe, steering gear and the subframe support must be correctly installed.

• Do not support the vehicle on the subframe or on the subframe support (for example, using a vehicle jack or something similar).

- Carefully lower the subframe using the Engine-/Gearbox Jack (V.A.G 1383 A) ; while doing this, pay attention to the clearance for the left hydraulic oil hoses and the right electrical wires.

- Let the subframe hang on the lower transverse link.

- Free up the electrical line on the lower left coolant pipe.






- Remove the bolt - 1 - (and if still not done, the bolt - 2 -) and remove the left lower coolant pipe from the coolant hose - left arrow -.

• In order to remove the coolant pipe, it may be necessary, depending on the flange shaft bracket, to loosen the bracket from the transmission and then turn it (do not remove bracket).

- Remove the coolant pipe.

- Remove the bolts - 2 - and remove the left engine support.






• Depending on the engine version, it may be necessary to use a M12 socket (multi-point socket) with a ball head to remove the top bolts on the engine support.

- Remove the left engine mount.

- Open the spring clamp - 3 -, pull the clamp - 2 - slightly out and remove the coolant hose.






• Disregard - item 1, 4 -.

Risk of damaging refrigerant lines and hoses.

• Do not stretch, kink or bend refrigerant lines and hoses.

- Remove the coolant pump housing.

- Remove the bolts - 1 - and - 2 -. Refer to => [ A/C Compressor Refrigerant Lines ] A/C Compressor Refrigerant Lines.






- Remove 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).

- Hold the compressor driveshaft - A - with a wrench and turn the compressor drive unit - B - in the direction of arrow - C -.






• Do not turn the compressor driveshaft - A -.

• Compressor driveshaft - A - can be slid into drive wheel through boot - E - after loosening threaded connection.

- Mark the electrical connector - 1 - for the A/C Compressor Regulator Valve (N280) (to prevent confusing it with other connectors which look identical).






• The connector to A/C Compressor Regulator Valve and the connector to the electric engine mounts are identical in construction. If these connectors are interchanged, no entry appears in the event memory. However since the A/C compressor is continuously activated, the evaporator may ice up.

- Disconnect the connector - 1 - for the A/C Compressor Regulator Valve from the bracket.

- Remove the bolts - 2 - and remove the compressor.

- Carefully push the subframe downward and them remove the A/C compressor to the rear (between the longitudinal member and the subframe).

Installing

Installation is done is reverse order, observe the following:

• There is an unspecified amount of refrigerant oil in the removed compressor so follow the information on replacing the compressor.

- If necessary, install the compressor driveshaft - A - (in the engine drive wheel) and check the grommet - E - seating.






• A clamp on the power take-off flange keeps the grommet - E - from sliding off. Refer to the Parts Catalog.

• The illustration shows the location of the components on a vehicle with a power steering pump. Only vehicles without electro-mechanical power steering have a power steering pump.

- If necessary, remove the alignment sleeves - F - from the compressor.






- Thoroughly clean the A/C compressor and bracket surfaces.

- Install the alignment sleeves - F - in the bracket or in the A/C compressor.

- Before tightening the A/C compressor, check seating of both alignment bushings - A - in bracket or A/C compressor - B -.






• The alignment sleeves - A - have different styles (different lengths), make sure to use the correct style. Refer to Electronic Parts Catalog (ETKA).

• Ensure bushings - A - are properly seated and contact surfaces are clean. Sockets installed incorrectly and dirty or damaged contact surfaces - C - on the bracket or A/C compressor can lead to alignment irregularities between the A/C compressor and engine. Alignment irregularities over operating time can lead to damage to the drive unit or the A/C compressor.

- Tighten the bolts - arrows -.






• Tightening specification: 25 Nm.

- Connect electrical connector - 1 - on A/C Compressor Regulator Valve.

- Check the A/C compressor connections and the refrigerant lines for damage or dirt. Refer to => [ A/C Compressor Refrigerant Lines ] A/C Compressor Refrigerant Lines.

- Connect the refrigerant lines to the compressor; bolt tightening specification - A -, for the O-ring dimensions - B - and - C - as well as additional information, refer to => [ A/C Compressor Refrigerant Lines ] A/C Compressor Refrigerant Lines and the Parts Catalog.






• Check refrigerant lines and their bracket for sufficient distances to other components. Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings.

- To prevent damaging the compressor the first time is it switched on, turn the compressor drive unit - B - on the compressor by hand 10 rotations in the direction of the arrow - C - before turning the compressor driveshaft - A -.






• Refrigerant oil can collect in the compressor compression chamber after removing the compressor or adding new oil (for example, by blowing through the refrigerant circuit). Rotating forces the refrigerant oil out of the compression chamber.

- Hold the compressor driveshaft - A - with a wrench and turn the compressor drive unit - B - in the direction of arrow - D -.

• Tightening specification: 60 Nm.

• Do not turn the compressor driveshaft - A - when tightening.

• After installing, check installation position of grommet - E - on drive wheel.

• After installing the driveshaft - A -, check the boot - E - installation position.

- Install the left engine mount.

- Install the lower left coolant pipe.

- Install the subframe.

- Connect the suspension strut to the control arm.

- Install the stabilizer.

- Connect the CV joint to the steering gear.

- Install the power steering hydraulic oil pressure line.

- Install the longitudinal braces.

• Replace the seal; the self-locking nuts and the O-ring for the oil dipstick guide tube.

- Install the oil dipstick guide tube.

- Fill with coolant and bleed the coolant circuit.

- Evacuate and fill the refrigerant circuit.

- Install the remaining removed components.

- Check the Climatronic control module (J255) display and control head DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

- 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.

• Note the information regarding operating the A/C system after filling.