Compressor, 8-Cylinder

Compressor, 8-Cylinder

Remove the compressor with drive unit from the holder

• Compressor is driven via a toothed gear and an driveshaft - B -.





• Remove compressor.

• Compressor bracket, removing from engine and installing.

• To remove the compressor on vehicles with an 8 or 10 cyl. engine, the refrigerant circuit must be drained and then both refrigerant lines must be removed from the compressor.

Special tools, testers and auxiliary items required

• Engine Support Bridge (10 - 222 A)





• Hook (10 - 222 A /10)





• Engine Support Basic Set (T40091)





• Engine Support Supplement Set (T40093)





Removing

• The following workflow describes the removal of the compressor in a vehicle with a fuel injected (FSI) engine. The workflow may differ slightly in vehicles with an MPI engine.

- Drain the refrigerant circuit.

• Depending on the vehicle equipment, in certain vehicles it may be necessary to remove the bumper, loosen the front end module, and pull it forward as far as possible.

- Drain coolant.

- Loosen the hose clamps - 1 - on the coolant hose.





• Ignore - arrows -.

- Remove rear engine cover - arrows -.





- Disconnect coolant hose - 2 - from the coolant expansion tank.





- Loosen the coolant expansion tank - arrow - and disconnect the electrical connectors at the Low Coolant Level Indicator Switch (F66) at the bottom of the coolant expansion tank.

- Place the coolant expansion tank and connected hoses - 1 - and - 3 - to the side.

- Remove oil dipstick - 10 - from guide tube.





- Remove bolts - 2 - and - 5 -.

- Disconnect electrical connectors - 1, 3, 4, 6, 8, 9 - and free up wiring harness.

- Remove Hall sensor 2 (G163) - item 9 -.

• Ignore - 7 -.

- Remove bolt - 1 - and remove oil dipstick guide tube upward.





- Remove bolts - 2, 3, 4 - and pull the coolant pipe at lower left off the coolant hoses - lower arrow.

- Tilt the left coolant pipe slightly upward.

• Ignore - top arrow -.

- Pull off rubber seal - 1 - and remove plenum chamber cover - 2 -.





- Secure the Adapter (10 - 222 A /4) with the connector (T40091/3) and the supports (T40093/1) and (T40093/2)to the suspension strut domes.





• The supports are marked for the left and right vehicle sides.

- Install the remaining parts of the support bridge as shown in the figure. Position the supports (T40093/3) on the seam of the longitudinal member.





- Attach the Hook (10 - 222 A /10) to the left engine lifting eye.

- Pre-tension engine using spindles.

- Remove left and right stabilizer mount bolts - 1 - and - 2 -.





- Remove nut - 3 - at the engine mount lower left.





- Remove the bolts - 1 - and - 2 - and the left engine mount console.

- Disconnect the electrical connection - arrow - on the left engine mount.





- Remove bolts - 1 through 3 -.

- Remove the engine support with the left engine mount.

CAUTION!
Risk of damaging refrigerant lines and hoses.

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

- Remove the bolts - 1 and 2 - and the refrigerant lines from the A/C compressor => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.





• To prevent dirt and moisture from entering, seal open lines and connections with clean plugs or protective caps.

- 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.

- Mark the 2-pin connector to the A/C Compressor Regulator Valve (N280) (so it does not get transposed with the connector to the engine mount).

- Remove the electrical connector - 1 - for the A/C compressor regulator valve (N280) from the bracket and disconnect it.





- Remove bolt - arrows -.

- Remove A/C compressor.

- Remove the alignment sleeves - F - from the compressor if necessary.





Installing

Installation is in reverse order, observing the following:

- Remove the alignment sleeves - C - from compressor bracket if necessary.





- Thoroughly clean contact surfaces - A - and - B - on bracket (and contact surfaces on compressor).

- Install alignment sleeves - C - into the compressor bracket (or the compressor).

• Ensure that alignment sleeves - C - have proper seating and 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.

• 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.

- If necessary, install the compressor driveshaft - A - (into the engine drive wheel) and check the seating and the accompanying grommet - E - => [ Compressor Drive Shaft, Loosening and Tightening ] Compressor Drive Shaft, Loosening and Tightening.





- Check whether alignment sleeves - F - are installed in the compressor bracket (or in the compressor).





- Check connections of compressor and of refrigerant lines for damage or soiling=> [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.

- Attach compressor to bracket with bolts - D - (and washers - E -).

- Tighten bolts - arrows -, torque: 25 Nm.





- Connect electrical connector - 1 - on A/C Compressor Regulator Valve (N280).

- Connect the refrigerant lines to the compressor (tightening torque of bolts - A -) => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor, O-ring seal dimensions - B - and - C - and additional information => [ Refrigerant Lines, Disconnecting and Connecting at Compressor ] Refrigerant Lines, Disconnecting and Connecting at Compressor.





• Check refrigerant lines and their bracket for sufficient distances to other components.

- 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.





• 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).

- Counterhold compressor driveshaft - A - using an open-end wrench and turn compressor drive unit - B - in - direction of arrow D -.

• 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 driveshaft - A -, check installation position of boot - E -.

• A clamp on the power steering pump prevents the socket - E - from slipping off. The clamp was used in production from MY 2006. Install it if necessary.

- Install engine support with left engine mount.

- Install the left engine console.

- 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 => [ A/C System, Operating after Filling Refrigerant Circuit ] A/C System, Operating after Filling Refrigerant Circuit