Compressor
Compressor
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Adapter (10-222 A/22)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Refrigerant circuit must be discharged to remove compressor from bracket in vehicles with 8 cylinder engine.
• 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 8 cylinder FSI engine, refrigerant circuit must be drained and then both refrigerant lines must be removed from compressor, refer to => [ Compressor ] Compressor.
Removing compressor with drive unit
- Discharge the refrigerant circuit.
- Remove noise insulation if necessary.
- Drain engine coolant.
- Remove front and rear engine covers.
- Remove left and right air filter housing.
- Remove nuts and bolts - arrows - of retaining clamps for refrigerant line.
• Bolts of retaining clamps for refrigerant line are removed so that the refrigerant lines can be pushed aside slightly and not damaged when inserting engine support bridge.
Preparatory work to remove left engine support:
• This Repair Manual only outlines the procedure to remove the left engine support, always refer to the respective Engine Mechanical Repair Manual to remove the left engine support.
- Position (10-222 A) with (10-222 A/22) and (T40091/3) on to bolted flanges of fender.
- Assemble the other components of (10-222 A) as depicted in the illustration. To do so, set the (10-222 A/19) on to seams of longitudinal member (pay attention to refrigerant lines on longitudinal member when doing this).
- Hang the hooks of the short spindle (10-222 A/10) into the left rear engine lifting eye.
- Slide the support (T40091/2) using slider (T40093/5) into both connectors (T40093/4).
- Assemble the long spindle from engine support sling (10-222 A) and hang the hook of the spindle into the left front engine lifting eye.
Secure support (T40091/2) using stud and cotter pins of connector (T40093/4).
- Pre-tension the engine by uniformly tightening both spindles.
- Remove guide for oil dipstick.
- Remove supply pipe to power steering system.
- Disconnect coolant hose - hoses -.
- Loosen left coolant hose and remove associated hose from coolant regulator.
- Remove nuts and bolts - 1 - to - 5 - and remove left engine support.
- Disconnect the connector from the Refrigerant Temperature Sensor (G454) - 1 -, refer to => [ Refrigerant Temperature Sensor ] Refrigerant Temperature Sensor (G454).
- Disconnect both refrigerant lines - 2 - and - 3 - from compressor, refer to => [ Compressor Refrigerant Lines, Disconnecting and Connecting ] Compressor Refrigerant Lines, Disconnecting and Connecting.
• Seal open pipes and connections at condenser with suitable caps (to prevent dirt and moisture from entering).
• Do not bend, kink or stretch lines or hoses as refrigerant lines and refrigerant hoses may be damaged.
- Hold compressor driveshaft - A - in place using an open-end wrench and turn compressor drive unit - B - in direction of arrow - C -.
• Do not turn the driveshaft - A -.
• Input shaft - A - can be slid into drive wheel through the boot - E - after loosening threaded connection.
- Mark the 2-pin harness connector - 1 - to A/C Compressor Regulator Valve (N280) (risk of interchange with harness connector to engine mount), refer to => [ A/C Compressor Regulator Valve, Checking Activation Signal ] A/C Compressor Regulator Valve (N280), Checking Activation Signal.
- Disconnect 2-pin harness connector - 1 - to A/C Compressor Regulator Valve.
- Remove three bolts - arrows - (tightening torque 25 Nm).
- Remove the compressor in a forward direction.
- Remove bushings - F - from compressor if necessary.
Installing the A/C compressor with the drive unit
• An uncertain quantity of refrigerant oil remains in a removed compressor, therefore observe notes for replacing the compressor.
- Remove bushings - C - from compressor bracket if necessary.
- Thoroughly clean contact surfaces - A - and - B - on bracket (and contact surfaces on compressor).
- Install bushings - C - into compressor bracket.
• Ensure that bushings - C - have proper seating 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.
• The bushings - C - have different styles (different lengths), make sure to use the correct style.
- If necessary, install compressor driveshaft - A - (into drive wheel of engine) and check seating as well as the associated boot - E -.
• Currently, the boot - E - is secured against slipping by a clamp on flange of drive toothed gear - C - of engine.
- Check connections of compressor and of refrigerant lines for damage or soiling.
- Install compressor with bolts - D - (and washers - E -) on to bracket (tightening torque of bolts - D - 25 Nm), pay attention to bushings - F - while doing this.
- Install refrigerant lines (with new, lightly oiled O-ring seals) on to compressor, refer to => [ Compressor Refrigerant Lines, Disconnecting and Connecting ] Compressor Refrigerant Lines, Disconnecting and Connecting (tightening torque of bolts - A - 20 Nm).
• Dimensions of O-ring seals - B - and - C -, refer to the Electronic Parts Catalog.
• The bushings - F - have different styles (different lengths), make sure to use the correct style. Refer to Electronic Parts Catalog.
- Before screwing in the driveshaft, rotate compressor by hand (after installing) via the compressor drive unit - B - in direction of arrow - C - (to prevent damage to compressor when first switching on).
• By rotating, refrigerant oil which has accumulated in the compressor compression chamber in the removed compressor or after adding fresh refrigerant oil (for example, after blowing through the refrigerant circuit) is forced out of the compression chamber.
- 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 -.
- Install remaining components.
• Note tightening torques of removed bolts and nuts.
- Add coolant and bleed cooling circuit, refer to => [ Coolant System, Bleeding ] Coolant System, Bleeding.
- Empty and fill refrigerant circuit.
- Check the DTC memory for the Climatronic Control Module and erase any faults displayed if necessary using the 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 => [ A/C System, Operating after Filling Refrigerant Circuit ] A/C System, Operating after Filling Refrigerant Circuit.