A/C Compressor: Installing

CAUTION:

If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE .
The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.

NOTE:

When replacing multiple A/C system components, refer to the refrigerant oil capacities chart to determine how much oil should be removed from the new A/C compressor. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE .

Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets may result in a refrigerant system leak.

-- If the A/C compressor (7) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

CAUTION:

A stud with integral spacer (4) is used at the lower rear of the A/C compressor. Always use the fastener designed for this location. Failure to reinstall the stud with spacer will cause serious compressor and accessory drive damage.

If removed, install the two studs (3) and one spacer stud (4). Be sure to install the spacer stud in the location shown.

-- Position the A/C compressor onto the engine and tighten the nuts (4) and bolts (3) in the following sequence:

Install the bolt and hand tighten.
Install the nuts and hand tighten.
Tighten front 8 mm nuts to 23 Nm (17 ft lbs).
Tighten rear upper 10 mm bolt to 40 Nm (30 ft lbs).
Tighten rear lower 10 mm stud with spacer to 40 Nm (30 ft lbs).

-- Connect the wire harness connector (1) to the A/C compressor clutch coil.

Fig 1: Identifying A/C Compressor, Wire Harness Connector, Bolt And Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the accessory drive belt. Refer to Removal and Installation .

-- Install the splash shield onto the right side frame rail. Refer to Removal and Installation .

-- Lower the vehicle.

Fig 2: Identifying A/C Discharge Line, Suction Line And Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.

-- Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

-- Install the A/C discharge line (1) and the A/C suction line (5) onto the A/C compressor (3).

-- Install the nuts (2 and 4) that secure the A/C discharge and suction lines to the A/C compressor. Tighten the nuts to 23 Nm (17 ft lbs).

-- Connect the negative battery cable.

-- Evacuate the refrigerant system. Refer to REFRIGERANT SYSTEM, EVACUATE .

-- Charge the refrigerant system. Refer to REFRIGERANT SYSTEM, CHARGING .

CAUTION:

If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE .
The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.

NOTE:

-- If the A/C compressor (1) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to the refrigerant oil capacities chart to determine how much oil should be added to the refrigerant system. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Refer to A/C REFRIGERANT OIL .

-- Position the A/C compressor onto the engine.

-- Install and tighten the bolt (2) and nuts (3) in the following sequence:

Install bolt and hand tighten.
Install nuts and hand tighten.
Tighten upper nut to 23 Nm (17 ft lbs).
Tighten lower nut to 23 Nm (17 ft lbs).
Tighten rear bolt to 23 Nm (17 ft lbs).

-- Connect the wire harness connector to the A/C compressor clutch coil.

Fig 1: Identifying A/C Compressor, Wire Harness Connector, Bolt And Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the accessory drive belt. Refer to Removal and Installation .

-- Install the splash shield onto the right side frame rail. Refer to Removal and Installation .

-- Lower the vehicle.

-- Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.

-- Install the A/C discharge line (1) and the A/C suction line (5) onto the A/C compressor (3).

-- Install the nuts (2 and 4) that secure the A/C discharge and suction lines to the A/C compressor. Tighten the nuts to 23 Nm (17 ft lbs).

Fig 2: Identifying A/C Discharge Line, Suction Line And Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the negative battery cable.

-- Evacuate the refrigerant system. Refer to REFRIGERANT SYSTEM, EVACUATE .

-- Charge the refrigerant system. Refer to REFRIGERANT SYSTEM, CHARGING .