Audi Workshop Service and Repair Manuals

Removing and installing air conditioner compressor (vehicles with 8-cyl. FSI engine) Special tools and workshop equipment required

t  Support bar -10- 222 A-

t  Supplementary engine support bar set -T40093-

t  Engine and gearbox lifter -V.A.G 1383 A- Removing –  Move the front wheels to straight ahead position. –  Switch off the ignition.   Caution Danger of destruction of electronic components Heed the action to be taken when disconnecting the battery. –  Disconnect the battery → Electrical system; Rep. gr.27.

–  Detach the engine cover -arrows-. –  Drain the refrigerant circuit → Air conditioner with refrigerant R134a.   Note Depending on the position of the service connection at the refrigerant line and the vehicle model, it may be necessary to remove the additional body brace stiffener on the left to permit connection of the service coupling of the air conditioner service station (e.g. on the Audi Q5) → Running gear; Rep. gr.40 and → Air conditioner with refrigerant R134a –  Drain the coolant → Engine, mechanics; Rep. gr.19.

–  Remove the front wall of the plenum chamber -A- → General body repairs, exterior; Rep. gr.50.

–  Detach the coolant hose at the top -right arrow- from the engine.   Note This coolant hose is removed together with the coolant pipe. –  Remove the bolt -2-.

–  Screw out the bolt -arrow-. –  Pull the dipstick guide tube -1- out of the top part of the sump.

–  Position the support bar -10- 222 A- with the adapters -T40093/6- on the left and right suspension strut domes as shown. –  Engage the spindles -10- 222 A /11- at the engine lifting eyes. –  Pre-tension the engine slightly with the spindles. –  Remove the front left and right wheels. –  Remove the left and right wheel housing liners → General body repairs, exterior; Rep. gr.66. –  Unscrew the drive shafts on the left and right from the gearbox flange shafts → Running gear; Rep. gr.40.

–  Screw out the bolt -arrow- for the power steering hydraulic fluid pressure pipe → Running gear; Rep. gr.48.   Caution Risk of damage to airbag coil connector t  Only separate the universal joint from the steering box with the front wheels in the straight ahead position. t  The steering wheel and steering box positions are then no longer to be altered (fix the steering wheel in position with adhesive tape if necessary).

–  Screw out the bolt -arrow- for the universal joint → Running gear; Rep. gr.48. –  Press the universal joint off the steering box and slide it upwards as far as it will go.

–  Disconnect the vacuum hose -1- and lay bare the power steering hydraulic fluid hose -arrow- at the holder → Running gear; Rep. gr.48. –  Unscrew the nuts -2- and detach the vacuum reservoir.

–  Unplug and lay bare the connector -1- at the steering box.   Note -Item 2- can be ignored. –  Lay bare the power steering hydraulic fluid hose on the left of the subframe. –  Lay bare the wiring on the right of the subframe.

–  Unscrew the earth wires -arrow- from the right longitudinal member.

–  Screw out the bolts -1-, unscrew the nuts -3- and detach the longitudinal members -2- on the left and right → General body repairs, exterior; Rep. gr.50.

–  Unplug the connector at the front left vehicle level sender -G78- and lay bare the wiring -arrow-.

–  Unplug the connector -3- for the left electrohydraulic engine mounting solenoid valve -N144-. –  Screw out the bolt -4- for the left engine mounting.   Note -Items 1, 2- and the -arrows- can be ignored.

–  Unplug the connector -2- for the right electrohydraulic engine mounting solenoid valve -N145-. –  Screw out the bolt -1- for the right engine mounting → Engine, mechanics; Rep. gr.10.   Note -Items 3, 4- and the -arrows- can be ignored.   Caution Risk of accident if the subframe is not secured. Always provide support for the subframe when pulling out the subframe bolts.

–  Support the subframe with the engine and gearbox lifter -V.A.G 1383 A- as shown → Engine, mechanics; Rep. gr.10.

–  Screw out the anti-roll bar bolts -3- on the left and right → Running gear; Rep. gr.40. –  Unscrew the nuts -1- on the left and right and pull out the suspension strut bolts -2- → Running gear; Rep. gr.40.

–  Unscrew bolts -1 ... 3- on left and right in stages.   Caution Risk of damage to running gear components t  If the vehicle is to be set down on its wheels, the entire subframe mounting, the steering box and the cross brace for the subframe must have been properly fitted. t  Supporting of the vehicle at the subframe or subframe cross brace (using a trolley jack or the like) is not permissible. –  Carefully lower the subframe with the engine and gearbox lifter -V.A.G 1383 A-, paying attention to the clearance of the hydraulic fluid hoses on the left and the wiring on the right → Running gear; Rep. gr.40. –  Leave the subframe hanging from the lower transverse links.

–  Lay bare the wiring at the coolant pipe at the bottom left. –  Screw out the bolts -1- (and the bolt -2- if this has not already been done) and detach the bottom left coolant pipe from the coolant hose -left arrow-.   Note Depending on the design of the mounting bracket of the left flange shaft, removal of the coolant pipe may involve unfastening the mounting bracket from the gearbox and turning it round (do not remove the mounting bracket) → Gearbox; Rep. gr.39 –  Remove the coolant pipe → Engine, mechanics; Rep. gr.19.

–  Screw out the bolts -arrows- and detach the left engine support.   Note Depending on the type of engine, removal of the upper engine support bolts may involve the use of an M12 screwdriver bit (multi-point socket) with ball head for example. –  Remove the left engine mounting → Engine, mechanics; Rep. gr. 10.

–  Remove the coolant hose by unfastening the spring clip -3- and pulling out the retaining clip -2- slightly → Engine, mechanics; Rep. gr.19.   Note -Items 1, 4- can be ignored.   Caution Danger of damaging refrigerant lines and hoses. Take care not to strain, kink or bend refrigerant lines and hoses. –  Remove the coolant pump housing → Engine, mechanics; Rep. gr.19.

–  Screw out the bolts -1- and -2- → Chapter (Detaching refrigerant lines at air conditioner compressor/attaching). –  Detaching refrigerant lines from air conditioner compressor.   Note Seal open lines and the connections at the air conditioner compressor with suitable caps (to prevent the ingress of dirt and moisture).

–  Hold the air conditioner compressor drive shaft -A- with an open-ended spanner and turn the air conditioner compressor drive unit -B- in -direction of arrow C-.   Note t  Do not turn the air conditioner compressor drive shaft -A-. t  After unfastening the screw connection, the air conditioner compressor drive shaft -A- can be pushed through the socket -E- into the drive gear.

–  Mark the connector -1- for the air conditioner compressor regulating valve -N280- (to avoid possible interchange with other identical connectors).   Note The connectors to the air conditioner compressor regulating valve -N280- and the electric engine mounting are identical. If the connectors are interchanged, no entry is made in the event recorder, but the evaporator may ice up as the air conditioner compressor is constantly actuated. –  Remove the connector -1- for the air conditioner compressor regulating valve -N280- from the holder and unplug it. –  Screw out the bolts -arrows- and detach the air conditioner compressor. –  Carefully press down the subframe and remove the air conditioner compressor to the rear (between the longitudinal member and the subframe). Installing Install in reverse order, paying attention to the following:   Note The air conditioner compressor removed contains an indeterminate amount of refrigeration oil. Attention is therefore to be paid to the notes on air conditioner compressor replacement → Air conditioner with refrigerant R134a.

–  If necessary, install the air conditioner compressor drive shaft -A- (in the drive gear) and check both proper attachment and the corresponding socket -E-.   Note t  The socket -E- is secured in position at the power take-off flange with a clamp to stop it slipping → Engine, mechanics; Rep. gr.15 and → Electronic parts catalogue. t  This illustration shows the layout of the components on a vehicle with vane pump. The vane pump is only fitted on vehicles without electromechanical power steering → Running gear; Rep. gr.48.

–  If necessary, remove the dowel sleeves -F- from the air conditioner compressor. –  Thoroughly clean the contact surfaces at the air conditioner compressor and holder. –  Fit the dowel sleeves -F- in the holder or air conditioner compressor.

–  Before securing the air conditioner compressor, check the position of both dowel sleeves -A- in the holder or air conditioner compressor -B-.   Note t  There are different versions of the dowel sleeves -A- (different length). Attention is therefore to be paid to the correct version → Electronic parts catalogue. t  Pay attention to correct positioning of the bushings -A- as well as to clean contact surfaces. Incorrectly fitted bushings and dirty or damaged contact surfaces -C- at the holder or air conditioner compressor can lead to misalignment between the air conditioner compressor and engine. In the course of operation, misalignment results in drive unit or air conditioner compressor damage.

–  Tighten the bolts -arrows-. l  Tightening torque: 25 Nm –  Plug in the connector -1- at the air conditioner compressor regulating valve -N280-. –  Check the connections of the air conditioner compressor and the refrigerant lines for damage or contamination → Chapter.

–  Attach the refrigerant lines to the air conditioner compressor. For the tightening torque of the bolts -A-, the dimensions of the O-rings -B- and -C- and additional information, refer to → Chapter and → Electronic parts catalogue.   Note Check that there is sufficient clearance between the refrigerant lines and the corresponding holders and the other components. Moisten the O-rings slightly with refrigeration oil before fitting → Chapter.

–  To avoid compressor damage on initial activation, give the air conditioner compressor drive unit -B- 10 turns by hand in -direction of arrow C- at the air conditioner compressor before screwing in the air conditioner compressor drive shaft -A-.   Note Any refrigeration oil which has collected in the air conditioner compressor removed or in the compression chamber of the air conditioner compressor after pouring in fresh refrigeration oil (e.g. after blowing out the refrigerant circuit) is forced out of the compression chamber by the cranking action. –  Hold the air conditioner compressor drive shaft -A- with an open-ended spanner and turn the air conditioner compressor drive unit -B- in -direction of arrow D-. l  Tightening torque: 60 Nm   Note t  Do not turn the air conditioner compressor drive shaft -A- when tightening. t  After fitting, check the installation position of the socket -E- on the drive gear. t  After fitting the drive shaft -A-, check the installation position of the socket -E-. –  Fit the engine support with the left engine mounting → Engine, mechanics; Rep. gr.10. –  Fit the bottom left coolant pipe → Engine, mechanics; Rep. gr.19. –  Fit the subframe → Running gear; Rep. gr.40. –  Screw the suspension strut to the track control link → Running gear; Rep. gr.40. –  Fit the anti-roll bar → Running gear; Rep. gr.40. –  Attach the universal joint to the steering box → Running gear; Rep. gr.48. –  Fit the power steering hydraulic fluid pressure pipe → Running gear; Rep. gr.48. –  Fit the longitudinal members → General body repairs, exterior; Rep. gr.50.   Note Replace the seal, the self-locking nuts and the O-ring for the dipstick guide tube. –  Fit the dipstick guide tube → Engine, mechanics; Rep. gr.17. –  Replenish the coolant and bleed the coolant circuit → Engine, mechanics; Rep. gr.19. –  Evacuate and charge the refrigerant circuit → Air conditioner with refrigerant R134a. –  Re-install the remaining components removed. –  Interrogate the event recorder of the operating and display unit, Climatronic control unit -J255- and erase any faults displayed → "Guided fault-finding" function of vehicle diagnostic, testing and information system VAS 5051. –  Start up the air conditioner after charging the refrigerant circuit → Chapter.   Note Also heed the notes on start-up of the air conditioner after charging → Air conditioner with refrigerant R134a.