A/C Compressor

NOTE:

Perform Guided Fault Finding A/C compressor first start whenever a new A/C compressor is installed.

Note the following on a vehicle with a Start/Stop System. Refer to START/STOP SYSTEM .

Removing

Special tools and workshop equipment required

Torque wrench V.A.G 1331/ (5 to 50 Nm)
A/C service station VAS 6007A or succeeding model.

NOTE:

Flush the refrigerant circuit with R134a refrigerant under the following conditions:

In the event of dirt or other contamination in the refrigerant circuit.

If vacuum reading is not maintained on evacuating a leak-free refrigerant circuit (pressure build-up due to moisture in refrigerant circuit).

If refrigerant circuit has been left open for longer than normal (e.g. following an accident).

If pressure and temperature measurements in the refrigerant circuit indicate the likelihood of moisture.

In the event of doubt about the amount of refrigerant oil in the circuit.

The A/C compressor had to be replaced on account of internal damage (e.g. noise or no output).

If only the auxiliary component bracket is being removed, it is not necessary to loosen the refrigerant lines on the A/C compressor. Attach the A/C compressor to the body with wire.

Fig 1: Identifying A/C Compressor, Securing To Body

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The procedure for flushing with R134a refrigerant, refer to REFRIGERANT CIRCUIT, FLUSHING WITH REFRIGERANT R134A .

Information for repairing vehicles with air conditioning and working with refrigerant, refer to A/C SYSTEM, REPAIR INFORMATION .

Information for special tools and equipment when repairing vehicles with air conditioning, refer to SPECIAL TOOLS .

-- Extract refrigerant e.g. using VAS 6007A, only then open the refrigerant circuit. Observe notes. Refer to REFRIGERANT CIRCUIT COMPONENTS .

Fig 2: Identifying A/C Compressor Remove/Install Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove noise insulation beneath engine. Refer to Description and Operation .

NOTE:

The right front wheel housing liner must be removed, depending on the engine. Refer to Removal and Installation .

-- Remove the ribbed belt. Refer to RIBBED BELT or RIBBED BELT .

WARNING:

There is a danger of ice-up.

Refrigerant leaks out if refrigerant circuit is not discharged.

Refrigerant must be extracted before opening refrigerant circuit. If refrigerant circuit is not opened within 10 minutes of extraction, pressure may form in refrigerant circuit due to evaporation. Extract refrigerant once more.

-- Remove the bolts -1- (22 ± 1 Nm) and disconnect the refrigerant lines from the A/C compressor.

-- Remove the bolts -2- (25 ± 2 Nm) and then remove the A/C compressor.

Installing

Fig 3: Identifying A/C Compressor Remove/Install Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolts -1- to 22 ± 1 Nm and the bolts -2- to 25 ± 2 Nm.

NOTE:

Perform Guided Fault Finding A/C compressor first start whenever a new A/C compressor is installed.

Make sure alignment bushings -3- are seated correctly.

Pay attention to notes for installing A/C compressor. Refer to A/C COMPRESSOR, INSTALLATION INFORMATION .

NOTE: Perform Guided Fault Finding "A/C compressor first start" whenever a new A/C compressor is installed.

- Secure bolts -1- (22 +/- 1 Nm) and bolts -2- (25 +/- 2 Nm).

- After installing a new A/C compressor or fresh refrigerant oil has been filled into compressor (for example after blowing through the A/C system), turn ribbed belt pulley of A/C compressor 10 rotations by hand before starting the engine. This prevents damage to the A/C compressor.

- Start the engine only after assembling the refrigerant circuit.

- Start engine with A/C compressor already turned off (indicator lamp button AC is off) and wait until the idle RPM as been attained.

- Open the instrument panel vents.

- Select the temperature setting "Lo" on the Climatronic A/C display control head -E87-.

- Turn on the A/C compressor (indicator lamp button AC is lit) and let the engine idle for at least 5 minutes.

NOTE:

The A/C compressor is always driven by the ribbed belt pulley (no A/C clutch).
If the A/C compressor is blocked, the compressor shaft overload protection is activated. The blockage is mostly recognized by deformations/bumps on the ribbed belt pulley. In addition, the blockage can be recognized by the abraded rubber in the area of the ribbed belt pulley.
The A/C compressor is equipped with a protected oil supply, this prevents A/C compressor damage in the event that the system is empty. This means that approximately 40 to 50 cm3 of refrigerant oil remains in the A/C compressor.
Only start the engine when the refrigerant circuit is filled.
The engine may only be started when the refrigerant circuit is installed correctly. 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.
A/C Compressor Regulator Valve -N280- is not activated when the refrigerant circuit is empty and the A/C compressor idles with the engine.
If it is necessary to start the engine with a discharged refrigerant circuit:
Refrigerant circuit must be fully assembled.
At least 1/4 of the prescribed refrigerant oil must be in the A/ C compressor.
Do not rev engine higher than 2000 RPM.
The engine should only run as long as is absolutely necessary, maximum 10 minutes.

- Perform remaining installation operations in reverse order of removal.