compressor, removing and installing (vehicles with 8...

Compressor, Removing And Installing (vehicles With 8 Cyl. Engine)

Removing (compressor driven via a shaft)

Discharge refrigerant circuit Refrigerant R134a - Servicing.Use flexible oil extractor V.A.G 1358/A to draw off power steering hydraulic fluidfrom

CAUTION: Hot vapor or hot coolant may escape on opening reservoir. Cover cap withcloth and open carefully.

Loosen cap of coolant reservoir.Unbolt front left wheel.

Loosen quick-release fasteners - 1 - , screw out bolts - 2 - and remove noiseinsulation.Remove front bumper.

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Remove left air guide - arrow - in front of auxiliary cooler.

Remove right air guide - arrow - in front of auxiliary cooler.Place drip tray V.A.G 1306 beneath engine.

Remove drain plug - arrow - at housing for thermostat and drain off coolant atengine.


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Remove coolant hose at bottom of radiator - arrow - and drain off remainingcoolant.Place oil drip tray beneath hydraulic lines to rear cooling line.

Disconnect hydraulic lines to rear cooling line at lock carrier - arrows -.

Remove cover - 1 - on right of engine compartment.


3 of 16 2/25/2012 5:24 PM

Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 -at air guide.Remove bolts - arrows -.Remove air guide - 2 -.

Remove coolant hose at top - arrow - of radiator.


4 of 16 2/25/2012 5:24 PM

Remove cover - 1 - on left of engine compartment.

Remove connectors - 1 - and - 2 - from bracket and disconnect.Expose bare wires to lock carrier.

Disconnect connector - arrow - for headlights on both sides of vehicle.


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Disconnect connector - arrow - for airbag sensors on left and right of lock carrier.Expose bare wires.Remove hood cable at lock carrier.

Disconnect connector - arrow - for fan on right.

Unbolt air guides on left and right of radiator - arrows -.

NOTE: To avoid damaging condenser and refrigerant lines/hoses, make sure lines andhoses are not strained, kinked or bent.


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Unbolt refrigerant line - arrow - to air conditioner compressor.

Unbolt refrigerant line - arrow - to air conditioner evaporator.


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Remove bolts - arrows - at lock carrier on left and right.Pull off hood seal at lock carrier and wing flanges.

Remove bolts at impact absorbers - arrows - on left and right.

NOTE: A second technician is required to remove the lock carrier.

Remove lock carrier and set down such that it cannot fall over.

Remove rear engine cover - arrows


8 of 16 2/25/2012 5:24 PM

Place support bar 10 - 222 A on wing mounting flanges.Engage hook of support bar in engine lifting eye.Use spindle of support bar to slightly pre-tension engine (do not raise).

Remove coolant hoses at locations marked with arrows.


9 of 16 2/25/2012 5:24 PM

Remove coolant hose at housing for thermostat - arrow

CAUTION: Take care not to kink or bend refrigerant lines.

Unbolt retaining clip - arrow - for refrigerant line at bracket on right.

Unbolt left bracket for refrigerant line - arrows -.


10 of 16 2/25/2012 5:24 PM

Remove bolts - 1 - and - 2 -.Remove refrigerant lines from air conditioner compressor and seal openconnections.

Unbolt nuts -1 to 4. for anti-roll bar mount on left and right.

Unbolt nut - 2 -Remove bolts - 1 - and - 3 - and remove engine bracket on left.


11 of 16 2/25/2012 5:24 PM

Disconnect connector - 1 - at engine mounting on left.Unbolt nut - 2 - and remove engine mounting.

NOTE: Shown with engine removed in illustration.

Remove bolts - 1 - and - 2 -.

NOTE: To stop fluid escaping, leave hose - arrow - connected to power steering.


12 of 16 2/25/2012 5:24 PM

Unbolt guide tube for dipstick at cylinder head - arrow - and lift it off.

Remove left engine support - arrows

Use open-ended wrench to hold compressor drive shaft - A - in position and turncompressor drive unit - B - in direction of arrow - C -.


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compressor drive unit - B - in direction of arrow - C -.

NOTE:

Drive shaft -A- must not be turned.After loosening threaded connection, drive shaft -A- can be pushed throughsocket - E- into drive pinion.Disconnect 2-pin connector to A/C Compressor Regulator Valve N280.

Remove bolts - D - (tightening torque 25 Nm ).Remove compressor towards frontIf necessary, remove bushings - F - from compressor.

InstallingBefore installing compressor Refrigerant R134a - Servicing

NOTE: The compressor removed contains an indeterminate amount of refrigerant oil.Attention is therefore to be paid to notes on compressor replacement Refrigerant R134a -Servicing.

Install compressor drive shaft (in drive pinion) and check both proper attachmentand corresponding socket.


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If necessary, remove bushings - C - from compressor bracket.Thoroughly clean contact surfaces - A - and - B - at bracket (as well as contactsurfaces at compressor).Fit bushings - C - in compressor bracket.

NOTE: Pay attention to correct positioning of bushings - C- as well as clean contactsurfaces. Incorrectly installed bushings or dirty/damaged contact surfaces could lead tomisalignment between compressor and engine. In the course of operation,misalignment results in drive shaft or compressor damage.

Check type of seal at connections and refrigerant lines (must be designed forsame type of seal).

Install compressor with bolts - D - (and washers - E -) to bracket (tighteningtorque 25 Nm ).Install refrigerant lines to compressor (tightening torque of bolts - A - 25 Nm ). Fordimensions of O-rings - B - and - C and further information.


15 of 16 2/25/2012 5:24 PM

After installation of a new compressor or after adding fresh refrigerant oil tocompressor (e.g. after blowing out refrigerant circuit), give compressor approx. 10turns by hand by way of compressor drive unit - B - in direction of arrow - C -before tightening drive shaft so as to avoid compressor damage.Tighten drive shaft. Use open-ended wrench to hold compressor drive shaft - A -in position and turn compressor drive unit - B - in direction of arrow - D -(tightening torque 60 Nm ).

NOTE:

Drive shaft -A- must not be turned.After installing drive shaft -A-, check installation position of socket - E-.Reinstall remaining components removed.Evacuate and fill refrigerant circuit. Refrigerant R134a - ServicingStart up air conditioner after mounting compressor.


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compressor, removing and installing (vehicles with 8...

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