Compressor, S8 10 Cylinder
A/C Compressor
Compressor, S8 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 an 10 cylinder engine, refrigerant circuit must be drained and then both refrigerant lines must be removed from compressor. Refer to => [ Refrigerant Lines, Disconnecting and Connecting from Compressor ] Removal and Replacement .
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Adapter (10 - 222 A /21)
• Used Oil Collection and Extraction Device (V.A.G 1782)
• Hose Clamp Pliers (V.A.G 1921)
• Spring Type Clip Pliers (VAS 5024A)
Removing
- Discharge refrigerant circuit.
- Drain coolant.
- Remove engine cover at front - 1 - and at rear - 2 - - arrows -.
- Remove left air filter housing.
- Extract hydraulic oil for power-steering from reservoir using Old Oil Collecting and Extracting Device (V.A.G 1782).
- Remove bolts - 2 - and - 3 -.
- Pull guide tube for oil dipstick off upward - arrow -.
• Ignore - item 1 - and - item 4 -.
- Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.
- Remove bracket for refrigerant line from left suspension strut dome - arrow -.
- Remove clip - 1 -.
- Disengage fuel line - 2 - and line to EVAP canister from bracket at right suspension strut dome.
- Remove rear bolts - 3 - for suspension strut.
- Secure Engine Support Bridge (10 - 222 A) with adapters (10 - 222 A /21) to suspension strut domes without cross-beam.
• The supports are marked for the left and right vehicle sides.
• Center support point - 2 - of supports is attached to front bolts for suspension strut dome.
• Adapters (10 - 222 A /21) are tightened using rear mounting bolts - 3 - for suspension strut dome.
• Knurled-head screw - 1 - must be turned downward far enough so that supporting plate makes contact on suspension strut dome.
- Secure spindles of Engine Support Bridge (10 - 222 A) to rear engine lifting eyelets.
- Pre-tension engine slightly using spindles on engine support bridge.
- Remove bolts - arrows - uniformly at left and right.
- Remove stabilizer..
- Remove bolts - 1 through 3 - on left and right and remove engine carrier.
- Remove nut - 1 - and bolt - 6 - and pull coolant pipe at lower left off coolant hoses - 2 through 5 -.
- Disconnect electrical harness connector - 1 - mark connector to avoid possible interchange.
- Remove coolant hose - 2 -.
- Remove bolts - arrows -.
- Swing After-Run Coolant Pump (V51) and disconnect from coolant hose - 3 -.
- Disconnect coolant hose - 1 - from radiator.
• Ignore - item 2 -.
- Disconnect electrical harness connector - arrow - at Engine Coolant Temperature (ECT) Sensor on Radiator (G83).
- 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 bolts - 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.
- Disconnect electrical harness connector - 2 - and remove engine mount from engine support.
- Unscrew bolts - arrows - and remove engine support.
- Remove supply hose.
- Remove pressure line banjo fitting - 2 -.
- Remove coolant hose - arrows - and place coolant pipe upward.
- 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 connector to prevent possible 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 from Compressor ] Removal and Replacement.
- 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.
- Attach the refrigerant lines to the compressor. Refer to=> [ Refrigerant Lines, Disconnecting and Connecting from Compressor ] Removal and Replacement (Bolts - A - tightening specification: 25 Nm), dimensions of O-rings - B - and - C - and additional information. Refer to => [ Refrigerant Lines, Disconnecting and Connecting from Compressor ] Removal and Replacement.
- 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 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 support.
- Install coolant thermostat housing.
- Install engine carrier.
- Install stabilizer.
- Install left air filter housing.
- Fill hydraulic fluid into power steering reservoir.
- Fill up coolant.
- Re-install remaining components removed.
- Empty and fill refrigerant 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 in the "Guided Fault Finding" function.
- Operate the A/C system after filling the refrigerant circuit. Refer to=> [ Operating A/C System after Filling Refrigerant Circuit ] Operating A/C System after Filling Refrigerant Circuit
• Note the information regarding operating the A/C system after filling.