RS5
A/C Compressor
Special tools, testers and auxiliary items required
• Engine Support Bridge (10- 222 A)
• Engine and Transmission Lifter (V.A.G 1383 A)
• Engine Support Supplement Set (T40093)
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.
- Left air filter housing, remove.
- Remove the bolt - arrows -.
- Remove the guide pipe - 1 - for the oil dipstick.
- 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 noise insulation - 1 - and - 2 -.
- Remove the left and right front wheels.
- Remove the left and right front wheel housing liners.
- Remove the left and right drive axles from the transmission flange shaft.
- Drain the coolant.
- Remove the left and right bolt - 1 - and nut - 3 - and then remove the brace - 2 -.
- Remove the nut - arrow - from the right longitudinal member and free up the ground cables.
- Disconnect the connector - 1 - from headlamp range control sensor 1 (G233) and free up the wire - arrow -.
- Remove the left and right bolt - 1 - from the stabilizer bar.
• Ignore - 2 and 3 -.
- Loosen the safety catch - arrow -, push the release down and disconnect the connector - 2 - from the steering gear.
- Disconnect the connector - 1 -.
- Free up the wiring harness.
- Remove the steering intermediate shaft from the steering gear and push them upward.
- Remove the bolt - arrow - from the ATF pipes.
- Remove the left and right bolts - arrows - and leave the heat shield - 1 - in its installed position.
- Disconnect the electrical connector - 3 - for the Left Electro-Hydraulic Engine Mount Solenoid Valve (N144).
• The connector to A/C Compressor Regulator Valve (N280) 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.
- 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 bolt - 1 - from the right engine mount.
• 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 (V.A.G 1383 A) as shown in the illustration.
- 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).
- Lower the subframe carefully using (V.A.G 1383 A). While doing this, make sure there is enough clearance on the left side for the ATF pipes and on the right side for the electric wires.
- Let the subframe hang on the lower transverse link.
- Remove the bolts - 2 - and remove the left engine support.
- Move the clamp - 1 - and open the clamp - 2 - and then remove the coolant hose.
- Move the coolant hose to the side.
- Open the clamps - 1 and 2 - remove the coolant hoses.
- Move the coolant hoses to the side.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- 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 screws - 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 to the Electronic Parts Catalog (ETKA).
• 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 subframe.
- Install the stabilizer.
- Connect the intermediate shaft joint to the steering gear.
- Install the ATF pipes.
- 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.
- 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.
- Check the DTC memory and erase any displayed entries. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".