V8 FSI
Compressor
Special tools, testers and auxiliary items required
• Engine support bridge (10- 222 A) with the respective supplement set
• Engine and transmission lifter (V.A.G 1383 A)
• Bit Xzn 10 (T10154)
• Locking Pliers (VAS 6199)
Removing
- Turn the front wheels so that they are straight.
- Switch off 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.
- Remove the right combination valve for secondary air injection.
- Remove the air hose from the left combination valve for secondary air injection.
- Remove the front left wheel housing liner.
- Completely remove the front noise insulation.
- Remove both air filters completely.
- Remove the fan shroud (with the coolant fans).
- Remove the pressure in the coolant circuit by opening the cap on the coolant expansion tank.
- Support the engine with the (10- 222 A) and the various adapters necessary for this vehicle.
- Remove the subframe completely with the steering gear and the lower support and guide arms.
- Remove the left engine mount.
- Remove the heat shield of the left axle shaft from the transmission.
- Remove the bolts - A - and - B -.
- Release clamp - D - and carefully push coolant hose - E - back (approximately 1 cm) until it can be securely fastened to coolant pipe - C - with clamp - D -.
Do not completely pull coolant hose - E - off of coolant pipe - C -.
• If coolant hose - E - is pulled off of coolant pipe - C -, all of the coolant escapes.
• Only push coolant hose - E - back far enough so that it can be securely attached with clamp - D - to coolant pipe - C -.
• Coolant pipe - C - must be detached so that the upper right bolt on the engine support (for example with the (T10154) ) - F - can be removed.
- Remove the bolt - arrows -.
- Remove the guide tube - 1 - for the oil dipstick from the upper part of the oil pan.
- Remove the bolts - 2 - and remove the left engine support.
• For the sake of clarity, this figure shows the engine support with the coolant pipe removed. However, the coolant pipe remains installed.
• The tightening specifications for the bolts of the engine support.
- Hold A/C compressor input shaft - A - with an open-end wrench and turn A/C compressor drive unit - B - with an open-end wrench 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 (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.
- Disconnect the connector - 1 - for the A/C Compressor Regulator Valve (N280) from the bracket.
- Remove the bolts - 2 - and remove the compressor.
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 => [ Refrigerant Lines at Compressor ] Refrigerant Lines at Compressor.
- Label the routing of the refrigerant lines to the other hoses and lines prior to removal (to ensure proper routing during reinstallation).
- 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).
- Carefully push the A/C compressor forward and remove it in a downward direction between the engine and front end module.
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.
• The boot - E - is secured against slipping by the clamp on the power steering pump flange, refer to Electronic Parts Catalog.
• If grommet - E - is damaged, replace it.
• To secure the clamp with the vane pump installed, use the locking pliers (VAS 6199) , for example.
- 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.
• 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.
- Check the A/C compressor connections and the refrigerant lines for damage or dirt, refer to => [ Refrigerant Lines at Compressor ] Refrigerant Lines at Compressor.
- Carefully install the A/C compressor in a forward direction.
- 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 => [ Refrigerant Lines at Compressor ] Refrigerant Lines at Compressor and Electronic Parts Catalog.
• Check the refrigerant lines for proper routing with respect to the other components.
• Coat the O-ring seals lightly with refrigerant oil prior to installation, refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-rings.
- Place the A/C compressor on the bracket and install and tighten the bolts - arrows -.
• Tightening specification of the bolts on the A/C compressor - arrows -: 25 Nm.
- Connect electrical connector - 1 - on A/C Compressor Regulator Valve (N280).
• Check refrigerant lines and their bracket for sufficient distances to other components.
- 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 open-end 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 support.
- Install the left engine mount.
- Install guide pipe - 1 - for the oil dipstick.
• Replace the seal; the self-locking nuts and the O-ring for the oil dipstick guide tube.
- Remove the heat shield of the left axle shaft from the transmission.
- Release clamp - D - and carefully push coolant hose - E - back onto coolant pipe - C - and secure with clamp - D -.
- Install bolts - A - and - B -.
- Install the left engine mount.
- Remove the heat shield of the left axle shaft from the transmission.
- Install the subframe completely with the steering gear and the lower support and guide arms.
- Evacuate and fill the refrigerant circuit.
- Install the remaining removed components.
- Check the event memory of the Climatronic control module (J255) , and erase any displayed malfunctions using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
- 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 operation of the A/C system after filling.