V8
Refrigerant Lines at Compressor
• Compressor is always driven when engine is running; there is no magnetic clutch. Engine is therefore not to be started unless refrigerant circuit has been properly assembled. For example; if the refrigerant lines are not connected to A/C compressor, when the engine is running the A/C compressor may heat up (via internal heat generation) so much that the A/C compressor will be damaged. Such internal heat generation results from the fact that - even with delivery near 0% - the compressor is confronted with a fixed resistance (sealed circuit).
• Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture).
Removing
- Switch off the ignition.
- Remove the pressure in the coolant circuit by opening the cap on the coolant expansion tank.
- Drain the refrigerant circuit.
8-cylinder FSI engine
- Remove the left air filter completely.
8-cylinder TFSI- engine
- Remove the front noise insulation - 1 -.
• Collect the drained coolant in a clean container for disposal or reuse.
- Place the drip tray for workshop cranes (VAS 6208) underneath.
- Lift up the retaining clip - 2 - to remove the coolant hose from the radiator.
• Ignore - item 1 -.
- Remove the bolts - 2 - and then remove the deflector plate toward the front - arrow -.
• Ignore - item 1 -.
- Disconnect the electrical connector - 3 -.
- Lift the retaining clips - 1 - to remove the coolant hose.
• Ignore - item 2 -.
For all vehicles
- Unscrew bolts - 1 - and - 2 - from above (between the left longitudinal member and the engine).
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
• To unscrew bolts - 1 - and - 2 -, the coolant hoses installed in this area must be carefully pressed to the side.
• To remove the refrigerant lines completely, label the routing of the refrigerant lines to the other hoses and lines prior to removal (to ensure correct 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).
Installing
Installation is done is reverse order, observe the following:
- Replace the O-rings - D - and - C -. Refer to Electronic Parts Catalog (ETKA).
• Do not use the O-rings from the sealing caps that are installed on the connections in the replacement compressor when installing the lines.
• Follow the instructions for installing the O-rings. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-rings.
- Check the guide ring - F - on the connections for both refrigerant lines - B - and - C - for damage.
- Clean the refrigerant line and A/C compressor connections and check for damage.
- Coat the O-ring seals with refrigerant oil prior to installation. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-rings.
- Insert the respective O-ring - D - and - E - into the groove - G - on the connections for both refrigerant lines - B - and - C -.
- Insert both refrigerant line into each connection on the compressor.
- Tighten bolts - 1 - and - 2 -.
• Tightening specification: 9 Nm (screws with an M6 thread) and 25 Nm (screws with an M8 thread).
• Following attachment of refrigerant pipes to compressor (and installation of compressor) check routing of pipes. They must be inserted in holders provided and not make contact with other components.
- Evacuate and fill the refrigerant circuit.
- Install the remaining removed components.
After completing the repair work, perform the following operations on the display control head. Refer to (Vehicle diagnostic tester) in the Guided Fault Finding function:
- Switch on the ignition.
- Check the event memory of the display control head, 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 operating the A/C system after filling.